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Discussion Starter · #1 ·
Finally found a ZF close by after looking for a month. The transformation has begun so I can finally drive it again. Had to tell someone

60k miles and the best part...............$500 :D
 

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Discussion Starter · #4 ·
Here is a copy of an email betwnne Damon Hass and myself. it beats typing it over again:flipoff2:
Howdy. Here is the story: Day after Xmas I blew the torque convorotr seal
which had to be pulled and fixed.$225 Bout a month ago I lost all forward
gears but still had reverse. Drove it 15 miles like that. Rebuild $1575.
So... I got pissed and started researching trannies. NP435, NV4500 I looked
at them all. The ZFS5-42 will prove to be the easiest swap because if you
have a 5.0 all you have to change is the flywheel and starter. That is what
I will be doing. If you have a 5.8 then it is a direct bolt it to the motor
and the 1356 OR 205 with a AA kit. . It can withstand a 10k trailer weight
so I hope that translates to being adequate for 37's. Also doing a SAS with
a 44 at the same time. I have been told that the existing tranny x-member
can be used but will not be able to confirm for a few weeks. Today I went
and got the tranny and man is it beefy. I got the tranny 60K miles),
pressure plate, pedal assembly, flywheel for $600. Plan on taking it apart
and doing seals and such. I plan on a Superforce clutch assembly and will
probaly be buying the hydrallic clutch parts and shifter new. I have a great
source for parts here in NC. I think the driveshafts will need slight
modification, probaly less than 2-3 inches. The slip may make up for that
will know problay in a few weeks. I will post on the board and will zap you
a copy of the write up. I did this simply because I can not see paying $1600
for a rebuild back to the level that I broke previously. The E40d in our
years was not built like the heavy duty ones in 95-96 which is still a POS.
But still this will be cheaper, and can withstand more punishment than the
auto. I hope!!!LOL

#2
http://www.drivetrain.com/transills542.html
http://www.sandstruck.com/catalog2000/ford/17.htm
http://www.lightruck.com/dr_gearratios.htm#ZF 5 Gas Underdrive

Are a few sites I have been using. It will say ZF S5-42 on the build plate.
There is a 4x4 and 4x2 model but it easily distinguished by the driveshaft
yolk vs. the connection for the x-case. You also have to get one for the
small block ford not the new 5.4 or the old 460. Has to be for the 5.8. I
found mine in a 92 F250. One of the above web sites has the ratios and other
info. The only thing I heard to look out for was cracks in the alum case.

For keeping yours cool, ditch the factory cooler and get a summit 24k cooler
or one with an elec fan. My parents put 50k a year on their E40D in a
superduty and a 32ft camper. It has worked well for 3 years and all the
people in their camping club use these auxilary coolers. I didnt listen
so...... I would definitely do
the biggest cooler you can wedge in there probaly in the engine compartment
away from the mud or between the frame rails if rocks only.
Any more questions feel free to ask.

I will have a write up for the board upon completion w/ part#'s, procedures and some pics.

Jeff
 

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Ditto on the big cooler for the E4OD. And don't bother with the built-in cooler in the radiator. Just bypass it. -- all it stands to do is transfer coolant heat (190F+) to the tranny fluid, which really shouldn't even be that warm.

Thanks Franklin. You wouldn't care to explain how you talked him down $300, would you? :flipoff2: (did you get pedal assy's for that price too?? :eek: )

Oh, and I'm willing to wager that if you can find the ZF (or maybe M5OD) crossmember, you'll be much happier. The E4OD crossmember is a bit of a road grader, particularly on the pass side.
 

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sclemons said:
Oh, and I'm willing to wager that if you can find the ZF (or maybe M5OD) crossmember, you'll be much happier. The E4OD crossmember is a bit of a road grader, particularly on the pass side.
LOL, you speaketh the truth!

Geeeez Shawn, you coulda had that very ZF for $500 if only you had been more persuasive....maybe you shoulda let Cyd talk sweet to the junkyard guy??
 

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Discussion Starter · #8 ·
I went up there in the damn snow on friday and walked around the junkyard, talked shit and scored. Took over 2 hours to find the tranny and other stuff. It had been there since 99 and I used my brother in laws business, Corley Body Works, as a business to business deal. So we just kept dickering around and stopped at 600 for the whole thing. Gonna be doing the e40d removal, take the ZF to the tranny guy and get going on this project this week.
 
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