1982 Ford Bronco: C6 to ZF5 4WD Swap Guide

Swapping a C6 transmission for a ZF5 in your 1982 Ford Bronco with a 351W is a great way to enhance your truck’s performance, especially if you’re looking for better gear ratios and improved drivability. Here’s a breakdown of what you’ll need to consider for this swap:

Parts and Equipment Required

1. ZF5 Transmission:

   • Make sure to source a ZF5 that’s compatible with the 351W. Check for one that includes the transmission harness and any necessary adapters.

2. NP208 Transfer Case:

   • You’ll need the NP208 transfer case, which is a great choice for 4WD. Be sure to get the correct adapter for the ZF5.

3. Adapter Plate:

   • An adapter plate will be required to connect the ZF5 to the NP208. These can often be found from specialty suppliers or online.

4. Transmission Mount:

   • The ZF5 will require a different transmission mount, so be sure to grab one that fits.

5. Driveshafts:

   • You may need to modify your existing driveshafts or get new ones to accommodate the different lengths and locations of the ZF5 and NP208.

6. Clutch Assembly:

   • Since you’re moving to a manual transmission, a new clutch kit, flywheel, and associated hardware will be necessary.

7. Pedal Assembly:

   • You’ll need a clutch pedal assembly, as the C6 is an automatic and the ZF5 is a manual.

8. Wiring and Linkage:

   • Make sure to check the wiring harness for compatibility. You might need to do some modifications for the new transmission. Also, ensure that the shifter linkage will work with the ZF5.

9. Crossmember:

   • You may need to modify or replace your existing crossmember to accommodate the new setup.

Tools Needed

• Basic hand tools (sockets, wrenches, screwdrivers)
• Transmission jack
• Torque wrench
• Engine hoist (optional, but helpful)

Step-by-Step Overview

1. Preparation:

   • Disconnect the battery and remove the C6 transmission and transfer case. Make sure to drain fluids and disconnect any wiring.

2. Install Clutch Components:

   • Install the clutch assembly and flywheel before the ZF5 is mounted.

3. Mount the ZF5:

   • Position the ZF5 onto the engine and secure it with the appropriate bolts.

4. Connect the NP208:

   • Attach the NP208 transfer case using the adapter plate you’ve sourced.

5. Modify Driveshafts:

   • Adjust and install the driveshafts to ensure proper alignment.

6. Install Pedal Assembly:

   • Install the clutch pedal assembly and modify the wiring harness as needed.

7. Final Checks:

   • Ensure all connections are secure, and fill all fluids before starting the vehicle.

Tips

• Documentation: Keep the service manuals handy for both the Bronco and the ZF5; they’ll help guide you through the swap.
• Community Resources: For additional insights and experiences, check out the Bullnose Ford subreddit or forums like Gary’s Garagemahal to see if anyone else has tackled a similar swap.
• Take Your Time: This swap can be quite involved, so take your time and double-check everything.

This is a comprehensive project, but with some patience and the right resources, you’ll have a Bronco that’s ready for any adventure! If you have any specific questions or need more details on a part of the process, feel free to ask!