He's better off than Jeff was with the locker. And Jeff made everything he tried but that one hill the first day on fins n things.

You might not know this... but I'm an expert at living my life with false hope..."Someday, just someday these Bronco guys will respect me"...

So guess I should update this thread with my ZF-5 install behind the 400. For full details you can find the thread here:

[url="http://classicbroncos.com/forums/showthread.php?t=228988"]http://classicbroncos.com/forums/showthread.php?t=228988[/url]

But heres the cliff notes :)

Decided I had enough of the NP435 and not only wanted overdrive but something that was a little more drivable. Decided to go with the ZF-5 behind a Ford 400. A few others have had great success with this conversion as the bellhousing on the 460 ZF-5 matches the 351m/400 engine block.

Although the ZF- will bolt up to the engine the input shaft is a bit too long causing the throwout bearing to fall off the input shaft and not allowing good pressure/clutch disk engagement. To solve this problem I had a spacer made that mounts to the front of the flywheel to the crankshaft and spaces everything back to allow good clutch/bearing engagement.

Anyway, here is the play by play...

Length of the 460 version of the zf-5 is 26.25"

I threw it in back of the Bronco and hauled it home





Custom spacer







Pulling out the bag of hammers...

Have everything ready to go to pull the trans and TC however after taking a look I think I will just drop the exhaust to get it out of the way.. anyway quit for the night it was getting cold out there.

Old stuff coming out.. nothing exciting...









ahhh so much better...





ZF-5 and NP435 side by side





Flywheel and spacer fitment.





[IMGhttp://www.almostmadeit.com/g/galleries/140110_ZF-5_Swap/ysune8uz.jpg[/IMG]

Back of the engine - pretty clean!



Spacer on the end of the crankshaft



Flywheel wheel and spacer mounted



ZF-5 in place, clears!



Getting the Dana20 ready for the zf-5 to D20 adpater.







Zf-5 mated to the Dana20 with the adapter



Twin sticks in! I must have mounted them 25 times to get them to fit right, had to bend, heat, cut and more to get them to work - but work beautifully now!



Rear output of the Dana20 - stepped up to a 1350 driveshaft



Working on the clutch linkage - going with a hydro clutch rather than a mechanical.



Clutch reservoir in place.



Clutch linkage - ended up with a threaded piece in the middle to be able to adjust if needed.



Fabbing up my transmission crossmember



Painted!



mounted



Had a bit of an issue finding a starter.. being a bit of a bone head finally tried the stock 400 starter and wouldn't you know.. its works! So found a mini 400/460 starter and got it mounted up.

Still need some final pictures and video, which hopefully I will have here soon but so far its working great, love the ZF-5.. just need to fab up a floor!

And.. finally got done with my suspensino fix/upgrade.

Got the Duff arms mounted, frame plated, Diff cover installed, new steering linkage / TRE's and lots of other stuff.





Heres my 7 bay garage where I work on the Bronco - fun times!



I was hoping that I could use the Bilstein 7100's I already had but after some measurements they were just too short. Ordered up some new 14" short body 7100's. I might be able to move the 12" Bilstein to the rear which would be fantastic. I will do some measurements when I remove em.

Anyway - going to re-install the air system, weld up the radius arm mounts, plates I added to re-enforce the frame and get the DOM supports for the upper shock mounts done this week.

Im mounting 12" bilsteins. They're pretty long, and will be up in the wheel well. Not sure if my solution will work of EB width axles, but I can make you some hoops if you want to try it.

Gotcha, that should make a difference. Sounds like a good plan.

Looks good Chris. But where are the flex pix?

Waiting on shocks and still need to weld stuff up ;)

Fabbing up my tunnel cover to cover up the holes cut into the floor board for the ZF-5 and transfer case.



got to use my shears! first time in 5 years...



next up is to cut out the shift areas and make the bends. Next I will take it to Line-x to see if they will shoot it to match the floor in the bronco..

got the floor patch in with the shift boots, works pretty good but will be taking the floor piece into line x to match the floor and help the heat and noise.







On the lookout for a bigger shift boot, will have to keep my eye out at the boneyard

Sweet, that looks great! Too bad it needs Line-X, it's kinda pretty.

Got the tunnel cover done.. like the way it turned out!





I might paint the screws eventually but kind of like the "rivet" look

It will look like the rest of the floor very soon :)

Yeah, good thing it's going to dusty Moab to make it match! Looks great. Nice piece there!

Opps.. too much fun in Moab ;)

Seems like the ZF changed the angle of the engine just enough to grab my fan shroud and eat the radiator..

Luck was with me as I found used radiator out of a 60s or 70s AMC (Maybe from a jeep wagoneer or something?) in the parts pile of a 4x4 shop in town, only radiator they had and unbelievable I got it to fit - bonus that the bronco mounts even worked. Made the repair on the trail and continued on - Matter of fact I ran Poison spider the next day...

I will have to take a picture next week when I pull it to put a new one in but its been patched twice (2 holes in it), it will be going on the garage wall as a "spare" :)

I will have to see if others have pictures of the actual carnage as someone took the fan to use as art...

anyway just ordered a new replacement from Summit and will be running a smaller spacer and clutch fan from now on...

Tell us that happened on carnage!

just the fan and radiator.. ordered a new radiator today from Summit should be here by Friday :)

So a quick update. Turned out the radiator was from Summit and cost $159 - shipped.. so replaced it with the exact same one.

While i had it out I took advantage of the extra space did some belt tightening, fixed my power steering lines running them slightly better and then installed a clutch fan that I have had hanging on the wall for about a year thanks to Zoso. So far so good, now I have to make a fan shroud which shouldn't' be too hard.



Heres the radiator I used - Jeremy and I found it besides a 4x4 shop in Moab.. its out of a 87 CJ-7



New radiator in...

*cool* (tongue in cheek)

On Track has some DIY shroud pieces on the shelf, I didn't check prices, but nice to have a local source.

I didn't know that. What pieces do they have? I've been contemplating making my own.

Cool will run over there and check them out. Was going to pick up some aluminum and have it tig welded

I think they have most of the pieces for a simple shroud.