So I found a deal I couldn't pass up. $800 for the transmission and transfer case from a 2002 6.8 ZF6!!! Gonna clean it up and start getting ready to install. Have to do a body lift here and start piecing together everything else. Any suggestions and help would be appreciated. I will make sure to document the whole process.

 

i think you will need to have new shafts built for you. different speedo drive between the 2 years as well. might have to rework the linkage for the transfer case shifter. not 100% but i think you will need to change out the slave and master as well.

 

Yea I was looking at that and saw that I am gonna have to do something about the shafts. This thing ways easily twice as much as the old one. haha. Can't wait to get this thing cleaned up and put in.

 

Just so you know your BW 4406 should bolt up to the ZF. You may still need to adjust the drive shaft lengths but you will not have the expense of having to switch sending units nor having to switch from a slip yoke to a flanged yoke. You will need to tinker with the t-case shift linkage.

 

I was wondering about that cause inside the bell housing it is different and it looks like the slave is inside the actual transmission but I could be wrong. And the transfer case has a flange and isn't a slip.

 

Your tranny ZF has an external slave. Here is a pic of a Superduty hydraulic system.




Your latest picture of the inside of the bellhousing shows a release lever. You will need a new release hub and the bearing.



Here is your pic with an arrow added to show where the external slave goes on the ZF.

 

Ok awesome!!! That helps out so much. I have been looking and looking for that info. I was hoping to get a look at this before it was out, but he already had it out.

 

the nice thing bout that sd master and slave is it comes pre bled from the factory. just lock it in and go. the slave is inserted into the bell at a 90deg angle and twisted into place. if im not mistaken that 6 speed uses SYNTHETIC fluid ONLY. double check your pilot bushing dimensions as well.

 

Yea I was gonna run synthetic anyways. And I plan on putting all new stuff in right away that way I don't have to worry about it and have to take it back out.

 

It looks as though it will bolt right up the only problem is that the BW is 31 spline and the ZF is 28 spline.

 

Son of a B. That sucks! So the 6 speed Gasser ZF has only 28 splines? I will have to do some more research.

 

Hold up I never counted just saw that there were less. They are actually 24 spline. But I have the transfer case with it so I think I may just use that. Gonna have to get new drive shafts either way cause the ZF is like 3 inches longer overall.

 

Did some quick research. Looks like the manual 6 speeds Gas and Diesel have have a 24 spline output shaft. The 5 speeds and Autos have 31 splines.

 

Ahh so a cheaper and easier maybe swap would be the 5 speed. But I already have the 6 speed and am set on it so keeping it. Gonna be a fun project. Little time consuming though, but thats ok. Once pay day gets here I am gonna order my body lift and do that so I have room for this huge thing. haha

 

The ZF6 takes Mercon ATF. Also, if you find a diesel 4x4 ZF6 for that price, lemme know.