Bullnose Bill Answer
by Ed

What parts and adjustments are needed to swap a ZF5 transmission into a 1985 Ford F150 4X4 with a T19?

Bullnose Bill assisting with a ZF5 transmission swap on a 1985 Ford F150, showcasing tools and parts laid out for the project.

This Q&A session is powered by Bullnose Bill, Bullnose Garage’s advanced AI mechanic.
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Bill says:

Hey there! It sounds like you’ve got an exciting project on your hands swapping your T19 for a ZF5 transmission in your ‘85 F150! The ZF5 is a great upgrade for more torque handling and smoother shifts. Let’s dive into what you’ll need for that swap.

Parts and Tools Needed for ZF5 Swap

1. Transmission and Adapter

  • ZF5 Transmission: Make sure it’s in good working condition.
  • Adapter Plate: If applicable, ensure it mates correctly with your 300 I6 engine.

2. Driveline Components

  • Driveshaft: As you mentioned, the length will likely need adjusting, so be prepared to either shorten or lengthen your driveshaft. You may also need to check the yoke compatibility depending on your new output shaft.

3. Transmission Mount

  • ZF5 Mounting Bracket: This may differ from your T19, so you might need a new transmission mount or an adapter for your existing one.

4. Shifter Assembly

  • ZF5 Shifter: The shifter location will likely be different, so you may need the ZF5 shifter and possibly a new boot.

5. Crossmember

  • Transmission Crossmember: You may need a different crossmember for the ZF5, as it’s generally positioned differently than the T19.

6. Bellhousing

  • Ensure you have the correct bellhousing that fits the ZF5 with your 300 I6 engine, as it can differ from the T19 bellhousing.

7. Clutch Components

  • Clutch Fork and Throw-out Bearing: You might need to replace these depending on the compatibility with the new transmission.
  • Clutch Disc: Check if the existing clutch disc is compatible. You may need to upgrade it for the ZF5.

8. Hydraulic System

  • If your ZF5 uses a hydraulic clutch, you may need a new master and slave cylinder setup. This might involve additional lines or a different pedal assembly.

9. Wiring and Sensors

  • Check for any wiring adjustments necessary for the new transmission, especially if your ZF5 has sensors or needs a different neutral safety switch.

10. Fluid

  • Transmission Fluid: Ensure you have the right fluid (usually ATF or 50W oil) for the ZF5, as it might differ from what your T19 requires.

Tools You’ll Need

  • Basic hand tools (wrenches, sockets, etc.)
  • Torque wrench
  • Transmission jack
  • Floor jack and jack stands
  • Snap ring pliers (if needed for driveshaft work)

Tips for the Swap

  • Take Your Time: This swap can be complex, so take your time to ensure everything fits properly.
  • Label Everything: As you disassemble parts, label them to make the reinstallation process easier.
  • Consult Forums: As you tackle this project, don’t hesitate to consult the Bullnose Ford subreddit or the F150 forum for specific guidance and tips from fellow Bullnose enthusiasts.

Make sure to document your process; it could be helpful for others in the community looking to do the same swap! If you have any more questions or need further details, feel free to ask. Happy wrenching!

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This answer was written by Bullnose Bill, our AI shophand trained on hundreds of Bullnose-era Ford topics. He knows his way around old Ford Trucks.

As with all of Bill’s answers, it has been reviewed and approved by Ed Zenisek, the man behind Bullnose Garage and a real human being.

While we do our best to keep things accurate, always double-check any repair advice and use proper safety procedures. For real-world walkthroughs and more hands-on content, check out Bullnose Garage on YouTube or visit the BullnoseFord SubReddit.

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