Hey everybody. Yeah i know, "another new guy" with another trans swap question that's probably been discussed on this forum numerous times. Any ways i have a 1995 F-150 2WD, 351Windsor, and an automatic trans (i think it has the E4OD) My question is is that i would like to convert it to a standard transmission. I read some info on this conversion a little bit but wasn't able to get evrything i needed to know. I would like to go with the zf 5spd out of a F250 or 350 as i heard the mazda 5spd in the f150 wern't that sturdy for the 351w. What years of the f250 and 350 with the zf 5spd would work on my f150? Does the zf have to come from a truck that had the 351w or can i use one from a truck that had the 460 or diesel? What about the trans crossmember and clutch/brake pedals. And what about the computer? Any insight or advice on this swap would be helpfull and very appreciated. Can i use the cluth and brake pedals from a 250 truck or should i take them out of a f150 that had the mazda 5 spd?

 

It would have to be from a 2WD with a 351 or a 300 I6. The 460's and the diesels have different bellhousing bolt patterns.

 

Good to know, thank you. One other thing i need to know for sure is what about the input shaft diameter and spline count on the ZF S5-42. Will it match up and work with my output shaft behind my 351w or is there a way to mix and match clutch parts? I know one version has the 1 1/4 input shaft and the other one has the 1 1/16". I'm not sure about spline count though. I'm kind of new with this stuff so any help is greatly appreciated. I'm just starting to gather all the parts together for this conversion and want to make sure i'm getting the right zf before i buy it and bolt it in without any problems. Thanks

 

Ok so i picked up a ZF S5-42 tranny from the scrap yard today for 300 bucks. Even came with the master/concentric slave cylinder, hydrualic line, shifter and boot, and crossmember isolator! It came out of a 1990 F-250 with a 351w. After doing hours of research on the internet on this swap i'm still kind of stumped with a few things. Are the flywheels different on a 351 with an auto trans vs a manual one? I would have to change flywheels right? The more i read into it the more confusing it gets for me. I have everything else pretty much figured out except for all the parts i need for between the trans and engine. Flywheels, clutch parts, can someone help me out it would be super appreciated. I'm probably going to give the zf a mild rebuild or atleast have it opened up and checked out. As for right now i'm still collecting the rest of the parts needed for this conversion except for what i need in the bell housing cuase i don't know.

 

So, got an update, TB? :)

Alvin in AZ

 

It's coming along, Slowly but surely. Got my clutch pedal in and the higher transmission hump plate put in. The clutch pedal was alot easier than i thought. Work has been kind of busy but it's going to slow down so i'll have some more time here soon to work on it.

 

Cool. :)

IMO, it's not a timed event. ;)

That's what my parts truck is too, a '90 F250 351w+ZF. :)

But mine was a beat to death "company truck" with 188k miles.

For ZF wear purpose a guy can at least double that mileage because
it was a company truck, I "drove ;)" those and wore out my share of
'em so, it serves me right to have to deal with a ZF out of one. ;)

http://www.panix.com/~alvinj/file12/Bronco2wd.jpg
http://www.panix.com/~alvinj/file12/hoist7m.jpg
http://www.panix.com/~alvinj/file12/hoist9m.jpg

The rear yoke on my ZF was damaged and so had to buy a new one.
The company mechanic had put 1+1/16" caps in where 1+3/16" caps
are needed and so ruined the yoke on the 10.25" axle too! :/

I don't know what size your '95 F150 uses but bet they're the 1+1/16"
size like my '91 Bronco uses. But that doesn't matter, your driveshaft
guy will take care of all that. :)

Chris' Machine Shop:
~$25(?) to resurface the flywheel

You're gonna need a flywheel and a manual starter too....
http://www.panix.com/~alvinj/file12/starters351w.jpg
...the short nosed one on the left is for a manual transmission.

Rockauto: (I searched under '90 F250 parts truck)
RhinoPac clutch kit 07057 $115 (LuK diaphragm-pressure-plate 'n disc)
RhinoPac slave S0707 $76
RhinoPac master cylinder M0706 $37
Dorman hydraulic line 628203 $28

McMaster-Carr:
6003 sealed ball bearing for clutch pilot bearing 6661K86 $22

I re-used the pressure plate bolts and flywheel bolts. :/

But this is what I bought to replace those when I rebuild the ZF...

Summit Racing:
ARP Pro-Series flywheel bolts 350-2802 $17
ARP pressure plate bolts 130-2201 $12 <-- these are Chevy bolts. :/

ARP doesn't list 3/8-16 bolts for Ford pressure plates. Pressure plate
bolts are "supposed to" have a shoulder on them. I believe these will
work and will work better than regular hardware store bolts but I just
plain old don't know for sure. I'll update this when I know something.

-----------------

I got drive shaft angles I want to work out first before replacing the
gears and bearings in the ZF.

Opening it up to have a look is easy! LOL :)
Knowing what you're looking at, is not so easy. ;)

My favorite ZF picture... :)
http://www.panix.com/~alvinj/file12/zf1.jpg

When taking this picture I was thinking "fun's over :/"...
http://www.panix.com/~alvinj/file12/zfF.jpg
...tinkering fools are like that.

I replaced all the synchro rings knowing at least 3rd gear's was shot,
put it back together and gave it a try. Mine needs the whole synchro
sleeve-hub-and-all for at least reverse and 3rd and bearings and the
bearings preloaded right. I'm going to get help in the form of advice
on that. :)

----------------------------

The input shaft on a '90 351w ZF is 1+1/16" with 10 splines just like
on my '75 360FE T-18. :)

Ford at least learned how to make -that- part "twice". ;)

Alvin in AZ