So having just completed the zf5 swap here are a few things I thought I would pass along.

No matter what everyone says you will want at least a 2inch body lift. Otherwise you will have a hell of a time getting the tranny connected and the shifter will hit the dash and the tcase will be in contact with the body. This was with the bc broncos xmember.

Whether you get the adapter to the d20 or just run the np tcase you will need your rear driveshaft shortened. You might be able to get away with leaving the front stock depending on lift

If you have true dual pipes on your truck you'll need to get that rerouted.

If you run the np tcase to get the shifter to work properly simply just flip the shifter and rebend the shifter rod to the other side.

The hydro clutch mod is super easy.

If you have the 74 and earlier manual steering don't convert it to 4x4x2 power prior to starting the zf5 swap because you believed the instructions that said you didn't need a body lift only to find out you did need a 2 inch lift. Otherwise the shaft you just cut to the perfect length is now a bit too short.


Speaking of 4x4x2, don't use the stock box front hole to locate the new box. Use the rear top hole. You will have to notch the body mount but this allows you slide the box further forward and results in better angles and tucks the box into a pocket in the core support that appears to have been built just perfectly for the 4x4x2.

Skip the plate on the outside of the frame and simply plate the inside of the frame.

The 4x4x2 box build is super easy and you can use the worm gear from any 4x4 Ford with ttb steering box. Ranger, explorer,bronco,fseries

Buy the seal/gasket kit its cheap and is good piece of mind.

Don't pay a lot for the boxes. I got both for 50 Bux. If you need a source lmk cause the guy I use has a shitload

If you have any questions feel free to ask.

HIX - interested in your contact for the steering boxes, I'll be starting a build this spring and it would be nice to have that part ready when needed. Mind sending me a pm with the info?

The guy's contact info is:

Jerry 303-842-8931
he is around College Ave and Federal if I remember correctly

Basically if you can think of anything ford truck 4x4 (fullsize) from 1970 to 1997 that you need I would bet that he has it. He is a little off his rocker but a real nice guy who just picks up ford 4x4 trucks and takes em apart. He sells axles (D60 and D44) for cheaper than anyone I have ever come across. If any part doesn't work properly bring it back and he will give you another one.

Pro tip:

If you call and he has a part the will usually give you a fantastic deal if you can pick up same day so don't bug him till you are ready to scoop it up. Don't try to low ball him on his already low prices. From the looks of his place dude is just barely scraping by and this is the kind of guy we want to keep around cause he literally has always had every single part I have ever called him about and knows everything ford related. You ask him for driveshafts from a 1978 hi-boy? he'll know right away to ask you if you need the ones with the big ujoint or the small ujoint.

I know him as Ed but its definitely the same guy! Great deals and he has everything! I replaced the entire front clip and both front doors on my truck from him. Power doors and everything in excellent shape for 150 total! Sells complete, running motors for 250 too! Great contact to have for anything ford truck related!

The bcbroncos one I have hangs maybe 1inch below the frame. I am building the np tcase support and will have a ramped skid plate to, but looking back I should have just built the xmember.

I shortened the dshaft 2inches because based off measurements this would prevent bottoming on full compression. I only have 3 inches of suspension lift so ymmv

I used the master and slave from the truck the zf came out of. I test drove it before pulling so it is known good. I'll have to pull the motor at the end of the summer so ill swap it and the clutch then.

It was a 3spd...haven't driven it yet as I need another manual steering shaft and the true dials rerouted

Here's the tranny and Atlas x-members I built







All covered up for a flat bottom:

sure wish i had the room and a muntion boss that wasnt on the side so i could build a sweet xmember like that

Thats some nice work Jesus_Man, What bushings did you use on that cross member?
Ray

It def looks sweet. I am gonna just end up with a s78 bronco stock style side bracket mounted to the top of the frame with one of the 3spd tranny bushings.