ZF5 Swap

[Justin]

The ZF5 fairy dropped off a transmission yesterday and I'd like to start sourcing the stuff I need. After breaking out the google-fu, it looks like I'll need:

-A custom crossmember
-Dana 20 adapter
-Clutch master cylinder
-Clutch slave cylinder
-Clutch hose
-Flywheel and clutch (as long as I've got it out).
-Brake pedal to swap for the current clutch pedal

Couple of other questions:
-I'll probably replace the clutch and flywheel while I've got everything apart. As long as I'm putting in a new flywheel can I swap for one matches the weight of my Explorer front dress and install the serp stuff at the same time?
-Any difference between the adapters sold by the various vendors? I'm assuming they're all the Advance Adapters part.

What am I missing? Anything else I should know about the swap?

[Eck]

While you're making a custom crossmember, just make 2.

[Justin]

Can do! Mine may have some added features, but they're not hard to do.

[Viperwolf1]

-I'll probably replace the clutch and flywheel while I've got everything apart. As long as I'm putting in a new flywheel can I swap for one matches the weight of my Explorer front dress and install the serp stuff at the same time?

No. The explorer parts are balanced for the late type 50 oz-in engine. If you don't have a late 5.0 it won't work unless you have the balancer re-balanced.

[Jesus_man]

Don't skimp on the Slave cylinder. I bought one from a chain parts store because I needed it in a pinch and it lasted a year...Not a fund job to do!

You've seen my cross-member? Pretty sure it's obvious I'm quite proud of it.

[ZOSO]

-I'll probably replace the clutch and flywheel while I've got everything apart. As long as I'm putting in a new flywheel can I swap for one matches the weight of my Explorer front dress and install the serp stuff at the same time?

No. The explorer parts are balanced for the late type 50 oz-in engine. If you don't have a late 5.0 it won't work unless you have the balancer re-balanced.

That's what he's asking. While putting in a 50oz flywheel swapping out the front dress to the explorer with the 50oz balancer.

So does that mean the crank is a neutral balance and you can change from 28oz to 50oz by swapping the flywheel and balancer?

[Kinder]

Do you have a body lift?

[akaFrankCastle]

As long as I'm putting in a new flywheel can I swap for one matches the weight of my Explorer front dress and install the serp stuff at the same time?

Short answer is no.

You motor was designed to use 28oz balanced components. Simply putting a 50oz flywheel and balancer on your motor doesn't mean it is now balanced for 50. It just means you're running the wrong stuff.

[Justin]

Gotcha, much appreciated.

[Eck]

When I had my engine apart, I had the machine shop rebalance the crank so that standard 50oz. components could be used. A lot easier to replace those than a crank down the road. If you are looking to just bolt on to your current motor, send the balancer to damper dudes.

[sykanr0ng]

While you're making a custom crossmember, just make 2.

+1 makes three please.

[Justin]

Sure. Once I mock up mine a few more will be easy. I bent up Landshark's and will probably do something similar for mine with the addition of tabs for a skid plate.

[Broncobsession]

Me too Iguana!

[Eck]

Sorry Justin. I was just being a smart ass, but now it appears you are too far in.

[Justin]

What they don't know is that they'll be $6,000 each.

Nah, we can work something out. I really might knock out a bunch of these to sell if I can figure good design that works well and isn't nuts to make.

[Justin]

Bump for a quick transmission moron question. I'm working on ordering some of the parts to install this beast. I should get a throwout bearing for ZF's donor, not an EB, correct? I'm planning to run an EB clutch. Also, should I pick up a pilot bearing as well? This is my first trans swap, so I've got no idea what I'm doing.

[Eck]

Bump for a quick transmission moron question. I'm working on ordering some of the parts to install this beast. I should get a throwout bearing for ZF's donor, not an EB, correct? I'm planning to run an EB clutch. Also, should I pick up a pilot bearing as well? This is my first trans swap, so I've got no idea what I'm doing.

I don't think you will need a new pilot bearing. You want to get the throwout bearing from the ZF donor vehicle. A lot of local parts places call it a Clutch Release Bearing and Slave Cylinder Assembly.

Also-- if I was you, I would get the clutch line from BCB - http://www.bcbroncos.com/store/product_ ... cts_id=519. Since it is a flexible line, it will be a lot easier to install and route. If you are ordering from BCB, you may as well pick up this gasket too (part #21-40118). I had to remove my shifter assembly to get it under my truck thus needing a new gasket.

Did your ZF come with the shifter?

[Justin]

No, no shifter. I'll need to hit the junkyard for one. Thanks for the info, that was exactly what I needed.

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[landshark]

Do you just need the handle or the whole shift fork that's mounted to the top of the Trans?

[Justin]

Just the handle. Was going to grab a boot as well, but that's flexible.

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[landshark]

i should have and extra of both the handle and boot.

[ZOSO]

Replace the pilot bearing now. Cheap insurance. If it fails it can trash the input shaft.

[Justin]

Chris, sweet, thanks! Rob, that's definitely the plan. The only wear item I'm not putting in new might be the clutch if my existing one is in good shape.

[Moab Mike]

Sure. Once I mock up mine a few more will be easy. I bent up Landshark's and will probably do something similar for mine with the addition of tabs for a skid plate.

If you need donor crossmembers I have several you can have. Yours for the asking.

[landshark]

i should be around this weekend Justin if you want to swap parts

[Justin]

Awesome, thanks!