Tag Transmission Swap

What should I know about the 1983 Bronco XLT with a 302 V8 and C6 transmission?


Bullnose Bill explaining the features of the 1983 Ford Bronco XLT.

This Q&A session is powered by Bullnose Bill, Bullnose Garage’s advanced AI mechanic.
Have your own question? Ask Bill!

Bill says:

Nice choice with the 1983 Bronco XLT! The 302 V8 paired with the C6 transmission is a classic combo that’s perfect for both on and off-road adventures.

What do you need help with today? Are you looking for maintenance tips, repair advice, or maybe some performance modifications? Let’s dive in!


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User:

How challenging is it to rebuild a 302 V8 engine?

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Bill:

Rebuilding a 302 V8 can be a rewarding project, especially if you enjoy getting your hands dirty and learning about your engine. While it can be challenging, many folks have tackled it successfully, especially with some patience and the right guidance. Here’s a breakdown to help you decide if it’s for you:

What Makes it Challenging?

  1. Tools & Equipment: You’ll need a good set of tools, including a torque wrench, engine hoist, and possibly a machine shop for tasks like boring cylinders or resurfacing the heads.

  2. Knowledge: Understanding the engine’s components and how they work together is essential. If you’re not familiar with engine assembly, it might feel a bit overwhelming at first.

  3. Time Commitment: Rebuilding an engine isn’t a quick job. Depending on your experience level, it can take anywhere from a weekend to several weeks.

The Rewards

  1. Learning Experience: There’s nothing quite like knowing your engine inside and out. You’ll learn a lot about how it operates, and that knowledge will help you down the road with maintenance and repairs.

  2. Customization: You can choose performance parts that suit your driving style, whether you want more horsepower, better fuel efficiency, or a bit of both.

  3. Satisfaction: There’s a unique satisfaction in knowing you rebuilt your engine and bringing your Bronco back to life.

Tips to Get Started

  • Gather Resources: Check out the Bullnose Garage YouTube channel for some hands-on tips and demonstrations. They often cover projects similar to this and can provide valuable insights.
  • Join the Community: Engaging with forums like the Bullnose Ford subreddit can connect you with others who have tackled similar projects. You can ask questions, share experiences, and get encouragement.
  • Follow a Manual: Invest in a repair manual (like the Haynes or Chilton) for your Bronco. It can guide you through the rebuild process step-by-step.

If you feel up for the challenge, go for it! Just take your time and don’t hesitate to ask for help when you need it. What part of the rebuild process are you most curious about?

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User:

How difficult is it to convert from an automatic to a manual transmission?

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Bill:

Swapping from an automatic to a manual transmission in your 1983 Bronco can be quite the project, but it’s definitely doable! Here’s a breakdown of what you can expect:

Challenges of the Swap:

  1. Complexity: This isn’t a simple plug-and-play job. You’ll need to consider several components beyond just the transmission, such as the clutch assembly, flywheel, and shifter.

  2. Parts Compatibility: Ensure that the manual transmission you choose (like a T18 or a ZF5) is compatible with your 302 engine. Some parts may need to be sourced from different vehicles or aftermarket suppliers.

  3. Wiring & Linkage: You’ll have to deal with the wiring harness since automatics typically use a different system than manuals. Plus, you’ll need to install a clutch pedal assembly and linkage, which can require modifications to your Bronco.

  4. Driveshaft: Depending on the length of the new transmission, you may need to adjust or replace the driveshaft to fit properly.

Rewards of the Swap:

  1. Driving Experience: Many enthusiasts feel that driving a manual transmission gives you more control and a more engaging experience behind the wheel.

  2. Performance: Manuals can sometimes provide better performance and fuel efficiency, especially if you enjoy off-roading.

  3. Simplicity: Fewer parts mean fewer potential problems. Manuals are often easier to work on and maintain in the long run.

Tips for a Successful Swap:

  • Research: Look into the specific manual transmission you want to install. There are plenty of resources available, including videos on the Bullnose Garage YouTube channel, that can guide you through the swap process.

  • Engage with the Community: Forums like the Bullnose Ford subreddit can be a treasure trove of information. Fellow enthusiasts can share their experiences and tips, which can save you a lot of time and hassle.

  • Gather Everything Upfront: Make sure you have all the necessary parts and tools before you begin. This will make the process smoother and less frustrating.

  • Consider Professional Help: If you feel uncertain about any part of the swap, consider consulting with a professional or a knowledgeable friend. It’s always good to have a second pair of hands and eyes on a project like this!

So, while it’s not the easiest task, many people have successfully made the switch and enjoyed the results. If you have any specific questions about the process or need advice on a particular aspect, just let me know!

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User:

What are the top upgrades for better fuel mileage?

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Bill:

Improving fuel mileage on your 1983 Bronco with the 302 V8 can be a fun challenge! Here are some effective upgrades and tips to help you get the most out of your fuel:

1. Fuel System Upgrades

  • Carburetor Tuning or Replacement: If your Bronco has a factory carburetor, consider tuning it for better fuel efficiency or swapping it for a more efficient aftermarket option (like a Holley). A well-tuned carb can significantly improve fuel delivery and overall performance.

2. Exhaust System

  • High-Performance Exhaust: Upgrading to a free-flowing exhaust system can improve engine efficiency. Look for headers and a low-restriction muffler that match your needs. This helps with exhaust flow and can lead to better fuel economy.

3. Intake Upgrades

  • Cold Air Intake: Installing a cold air intake can help your engine breathe better. Cooler air is denser and can lead to better combustion, improving mileage.

4. Electronic Ignition System

  • Upgrade to Electronic Ignition: If your Bronco is still using a points-style ignition system, consider upgrading to an electronic ignition. This can lead to more reliable spark and better fuel combustion.

5. Transmission Upgrades

  • Gear Ratio Optimization: If you’re running larger tires, consider re-gearing your differential to match. This can help improve your power band and fuel economy, especially at highway speeds.

6. Tire Maintenance

  • Proper Tire Inflation: Keeping your tires properly inflated can improve fuel efficiency. Under-inflated tires create more rolling resistance, which decreases mileage.

7. Regular Maintenance

  • Tune-Ups: Regular oil changes, air filter replacements, and spark plug changes can all contribute to better fuel economy. A well-maintained engine runs more efficiently.

8. Driving Habits

  • Smooth Driving: Change your driving habits by accelerating smoothly and maintaining a steady speed. Avoiding rapid starts and stops can lead to significant fuel savings.

9. Weight Reduction

  • Remove Unnecessary Weight: If you have extra gear or parts in your Bronco that you don’t use, consider removing them. Every bit of weight you can shed helps improve fuel efficiency.

Resources for More Information

For detailed guides and real-world experiences, you might want to check out the Bullnose Garage YouTube channel. They often cover upgrades and maintenance tips that could help with improving fuel mileage in classic Fords.

By implementing some of these upgrades and changes, you should see a noticeable improvement in your Bronco’s fuel economy. If you have any specific questions about a particular upgrade or need help with something else, just let me know!

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Is upgrading to EFI beneficial for increasing fuel capacity?

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Bill:

Upgrading to Electronic Fuel Injection (EFI) on your 1983 Bronco can definitely be worth it if you’re looking for increased fuel efficiency and overall performance. Here are some key points to consider:

Benefits of EFI Upgrade

  1. Improved Fuel Efficiency: EFI systems can provide better fuel atomization and more precise fuel delivery compared to carburetors. This often leads to improved fuel economy, especially during varying driving conditions.

  2. Better Throttle Response: EFI systems typically offer improved throttle response, making your Bronco feel more peppy and responsive when you hit the gas.

  3. Reliability: EFI systems are generally more reliable than carburetors, particularly in different weather conditions. They tend to start easier in cold weather and can adjust more effectively to changes in air density, temperature, and elevation.

  4. Less Maintenance: While carburetors can require frequent adjustments and cleaning, EFI systems are often more consistent over time, requiring less frequent tuning.

  5. Potential for Future Modifications: With EFI, you open the door for more advanced performance modifications. It’s easier to adjust your setup for performance upgrades if you decide to go that route in the future.

Considerations Before Upgrading

  1. Cost: EFI kits can be more expensive than traditional carburetor setups. You need to weigh the benefits against your budget. However, the potential fuel savings may offset the initial costs over time.

  2. Complexity: The installation process can be more involved than a carb swap, especially if you’re unfamiliar with EFI systems. You might need to modify or upgrade fuel lines, install a new fuel pump, and manage wiring for the system.

  3. Compatibility: Ensure that the EFI system you choose is compatible with your engine setup. There are several kits available specifically for classic Ford vehicles, which can simplify the process.

Conclusion

If you’re aiming for improved fuel efficiency and overall performance, upgrading to EFI can be a great investment for your Bronco. Many enthusiasts have found that the benefits outweigh the challenges and costs associated with the upgrade.

If you’re curious about specific EFI kits or need more details about the installation process, feel free to ask! There are also some informative videos and discussions available on the Bullnose Garage YouTube channel that can help you visualize the upgrade. Happy cruising!

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What is the ideal gear ratio for 35-inch tires?

Bill avatar
Bill:

When you upgrade to 35-inch tires on your 1983 Bronco, choosing the right gear ratio is crucial to maintaining optimal performance and fuel efficiency. Here are some guidelines to help you decide on the best gear ratio:

Recommended Gear Ratios

  1. 3.54:1: This is often a good starting point if you primarily drive on the highway and do some light off-roading. It provides a balance between power and fuel economy.

  2. 3.73:1: This is a popular choice for many 35-inch tire setups. It offers a bit more acceleration and torque without sacrificing too much fuel efficiency, making it suitable for both on-road and off-road use.

  3. 4.10:1: If you’re planning to do a lot of off-roading, this gear ratio can help provide better low-end torque, which is beneficial in challenging terrains. However, you may notice a slight decrease in fuel economy when driving on highways.

  4. 4.56:1: For those who prioritize off-road performance and have a more aggressive driving style, a 4.56 ratio can be advantageous. You’ll get great low-end power, but it might lead to higher RPMs on the highway, impacting fuel efficiency.

Factors to Consider

  • Driving Habits: If you primarily drive on the highway, you might want to stick with lower ratios like 3.54 or 3.73 to keep your RPMs down. If you’re off-roading or towing, consider higher ratios.

  • Engine Performance: The output of your 302 engine and any modifications you might have (like an EFI upgrade) can also influence the best gear ratio for your setup.

  • Transmission: Different transmissions have different torque characteristics, so be sure to consider how your C6 transmission will work with your chosen gear ratio.

Conclusion

Ultimately, the best gear ratio for 35-inch tires on your Bronco depends on how you plan to use it. If you’re looking for a balance between on-road comfort and off-road capability, a ratio like 3.73 or 4.10 is often a sweet spot.

Make sure to also consult resources like the Bullnose Garage YouTube channel or the Bullnose Ford subreddit for real-world experiences and insights from other owners who have made similar upgrades. If you have any other questions or need more specific info, let me know!



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.


As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.

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.
Have your own question? Ask Bill!

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!


This conversation had no additional replies.



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.


As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.

What does it take to swap a 1982 Ford Bronco from C6 to ZF5 4WD?


Bullnose Bill assists with the process of upgrading a 1982 Ford Bronco transmission.

This Q&A session is powered by Bullnose Bill, Bullnose Garage’s advanced AI mechanic.
Have your own question? Ask Bill!

Bill says:

I’m "Bullnose Bill," your friendly virtual mechanic specializing in classic Ford trucks, especially the iconic Bullnose models from 1980 to 1986. I’m here to help you with maintenance tips, repairs, modifications, and any questions you might have about these beloved vehicles. So, if you’ve got a question or need some advice, just let me know!


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User:

What is required to swap a 1982 Ford Bronco C6 to ZF5 4WD NP208?

Bill avatar

Bill:

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!



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.


As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.

ZF5 Transmission

Published on October 9, 2024

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Part of the Bullnose Era Transmissions series.

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Hi folks, Ed here. Welcome back to Bullnose Garage. And let me ask you a question: what’s the ultimate transmission for your old Ford truck? Something that will handle heavy loads, eat up the miles on the highway, but still give you that solid manual shifting experience that lets you know you’re driving a truck. The ZF5 transmission might just be the answer. It’s the heavy-duty overdrive gearbox that gave Ford trucks new life, and today we’re going to crack open everything you need to know about it. From finding one for your build to understanding what makes it appealing for a swap, we’re going to see if the ZF5 really is all it’s cracked up to be and why it’s still one of the most sought-after upgrades out there. Stick with me because we’ll also get real about why you might want to pass on it for options like the Mazda M5OD, TMIC TKO, or even the MV4500 from the other guys. By the end of this video, you’ll know exactly what you’re getting into.

Hello! Manufactured by ZF Friedrichshafen AG, the ZF5 is a 5-speed manual workhorse made for Ford trucks from the late ’80s through the late ’90s. The S542 was designed to replace the older four-speed gearboxes, offering better fuel efficiency and improved highway driving with its fifth gear. In the mid-1990s, the S547 came as an upgrade, increasing torque capacity from 420 lb-ft to 470 lb-ft. The ZF5 was built for heavy-duty stuff like towing and off-roading while providing a balance between low-end torque and cruising. The later S547, with its stronger internals, was better suited for powerful engines such as the big blocks or diesels, but both models are considered pretty heavy-duty.

So now let’s look at some key specifications for both versions of the ZF5. They were both a 5-speed manual with overdrive. Both had all forward gears synchronized for smoother shifting. The gear ratios between both are the same: first is 5.72 to 1, second is 2.94 to 1, third is 1.61 to 1, fourth is 1:1 or direct drive, fifth, which is overdrive, is 0.76 to 1, and reverse is 5.24 to 1. The case material is aluminum for strength, weight savings, and heat dissipation. It weighs right around 135 lb without fluid and it measures 26 1/2 in long, 16 1/2 in wide, and 17 in high. This compact size allows it to fit various Ford models in both 4×2 and 4×4 configurations. The transmission holds approximately 5 quarts, though this may vary slightly depending on the specific vehicle setup. It’s recommended to change the transmission fluid at every 30,000 to 50,000 miles under normal driving conditions. For trucks used in heavy-duty applications such as towing or off-roading, more frequent changes at every 20,000 to 30,000 miles isn’t a bad idea.

Now let’s talk about how the ZF5 feels to drive. One thing that sets it apart is its mechanical shift feel. If you’re used to a lighter-duty transmission, the shifts are a bit notchy, meaning there’s a more deliberate solid engagement as you change gears. That’s not necessarily a downside; it gives you a strong sense of connection to the truck, which many enthusiasts love. It’s a transmission that feels tough, though it requires a bit more effort to shift than a TREMEC TKO or an M5OD. The ZF5 transmission, which includes the ZFS 542 and S547 variants, has a typical 5-speed manual shift pattern, and here’s how the pattern is laid out: first gear is top left, second gear is bottom left, third gear is top middle, fourth gear is bottom middle, fifth gear, the overdrive gear, is top right, and reverse is bottom right. To engage reverse, you typically need to move the shifter to the far right and then down. Some versions of the transmission may require you to push down on the shifter or pull up on a collar to engage reverse, depending on the vehicle and the specific shifter setup.

Ford paired the ZF5 with multiple different engines. You’ve got the Windsor, the 5.0 L and 5.8 L, and you’ve got the 4.9 L 396. The big block pattern matches larger engines like the 7.5 L, which is the 460, and the diesel pattern is designed for the 7.3 L IDI Diesel and the 7.3 L Power Stroke diesel. Now let’s quickly talk about something else that’s crucial when considering the ZF5 transmission: whether or not it’s a 4×4 or a 4×2 version. They are not interchangeable. The 4×4 versions are designed to bolt to a transfer case and have a shorter output shaft, while the 4×2 versions are for two-wheel drive trucks featuring a longer output shaft and a different tail housing. So if you’re planning a swap, make sure you’re matching the transmission type to your truck’s drivetrain.

Between the three different bell housing patterns and the two different drivetrain configurations, there are six possible installation setups for a ZF5 transmission, so ensure you choose the right one if you’re doing a swap or buying a rebuilt unit. To simplify which Ford models came equipped with the ZF5, let’s look at this chart. It provides a full breakdown of every truck and van with the ZF5, the years they were available, and the bell housing patterns they used. It’ll help you pinpoint what you need to look for when hunting for one of these transmissions at a junkyard or a pick-a-part. As you can see, the ZF5 found its way into quite a few Ford models. First off, you notice the F250 and F350 are some of the main players here. If you’ve got a gas engine, these trucks are running ZF5 from ’87 to ’97 for the 250 and up to ’98 for the 350. They had the small block pattern for the earlier S542 models and the big block pattern with the S547 once it was introduced. When you jump over to the diesel trucks, the ZF5 was right there from the start, available with the 7.3 L IDI Diesel and later the Power Stroke model. So whether you’re working with an F250, F350, or even a bigger F450, you’ve got a solid spread from ’87 to ’98 for a diesel ZF5. For diesels, ZF5 trucks have the unique diesel bell housing pattern. The F-150 also occasionally came with the ZF5, particularly in the 5.0 L and 5.8 L engines, though it’s a bit of a rarer find and mostly in fleet trucks. If you’re thinking about the Bronco, it also had the small block ZF5 option, making it a great fit if you’re building a Bronco and you want that five-speed. Lastly, we can’t forget the E-Series vans, those E250s and E350s, which could come with a ZF5. They’re less common, but they did use the small block or diesel patterns depending on the engine under the hood.

If you’re planning a 4×4 build, you want to make sure that you think about transfer case compatibility with your ZF5. The two most common options are the BorgWarner BW1356 and the New Process NP205. The 1356 is a good choice for off-roading and it’s known for being lightweight and durable. The NP205, on the other hand, is a cast iron unit and considered nearly bulletproof. Each of these transfer cases bolts up to the ZF5 without major modifications, so long as you have a 4×4 compatible transmission. So it really comes down to the needs of your build and how you plan to use your truck.

Now let’s say you’re searching for a ZF5 in a salvage yard, swap meet, or online listing. How do you know you’re looking at? First, you look for the ZF logo cast on the side of the case; dead giveaway. Specific cast numbers can also confirm whether you’re looking at an S542 or an S547. Finally, and probably the easiest to see at a glance, check the case. It has a distinct crisscross rib design that makes it stand out from other transmissions.

So how much will a ZF5 cost you if you’re looking for one? As always, prices vary based on condition and location, but here’s a general idea: a used ZF5 transmission can run anywhere from $400 to $1,200 and sometimes higher depending on factors like mileage, configuration, and the variant you’re looking for. If you find one that’s been rebuilt or is in like-new condition, expect to pay more, anywhere from $1,200 on the low end to $2,500 on the higher end. If you’re looking to buy a rebuilt ZF5 from a reputable rebuilder, expect to pay between $1,500 and $3,000 depending on the level of work done, the rebuilder’s reputation, and whether they have done any performance upgrades that are included in the build. The bell housing pattern can also influence the price, and some are in high demand or can be harder to find.

But let’s say you find a deal on a ZF5 that needs a little bit of TLC. How much would it cost to rebuild it yourself? Well, rebuilding any transmission can be a big job, but if you’re hands-on and you’ve done some transmission rebuilds before, it’s possible with a DIY project. Parts and rebuild kits typically range from $400 to $600, with some kits including all the bearings, synchros, and seals. If your transmission requires more extensive work, like replacing damaged gears or shafts, costs can increase, potentially adding a few hundred in parts. Circling back around to the difficulty, if you’ve rebuilt manual transmissions before, the ZF5 isn’t too complex, but it does require precision and the right tools. A good shop press, snap ring pliers, and a bearing puller are all added to the app. For someone with solid mechanical skills, it’s a doable weekend project. However, if you’re newer to transmission work, you may want to consider having a professional handle it or guide you to the more intricate parts.

I would have somebody build it. As I’ve said before, the ZF5 is known for its durability, but like any mechanical thing, certainly transmissions, it has a few issues. Over time, you might experience shift fork wear, which when the forks guiding the gears wear down, causing poor shift quality. If it’s harder to shift into gear or you notice some sloppiness, worn shift forks are usually the culprit. Synchro wear is another issue, especially on second and third gears. Regular fluid changes can help extend the life of your ZF5, but if trouble arises, it might be time for a rebuild. And finally, listen for input shaft bearing noise. A whining or grinding sound under load could indicate a worn input shaft. Replacing it during a rebuild is a good idea to keep your ZF5 running smoothly and quietly. I mean, you know, unless you want to have a manual transmission.

Both the ZFS542 and S547 are pretty good right out of the gate as far as upgrades, but several aftermarket options are available to make it even better. For instance, upgrading to a heavy-duty clutch can improve the transmission’s ability to handle higher torque levels, particularly in the S547, which may be used in truly tough situations. You can also install a short throw shifter; this can reduce shift time and effort, making the transmission more responsive and enjoyable to drive. It takes away some of that truck feel but makes it a little bit more sporty, although it’s never going to be sporty. Finally, adding an external transmission cooler can manage heat in demanding situations and extend the life of your ZF5.

Okay, now for some comparisons. If you’re considering a ZF5 for a swap, don’t miss this. I’m going to quickly compare how the ZF5 stacks up against a few other options and see why you might choose one over the other. So I’m going to start with my situation; that’s the NP435. That’s what I have in mind. I’m thinking about going to a ZF5. It’s a four-speed manual with a low first granny gear; it’s around 6.68 to 1, makes it great for heavy-duty stuff like towing or off-roading. But without overdrive, it’s not ideal for highway driving or even going around town, and that’s where the ZF5’s fifth gear shines. Shift points on the ZF5 are also better space for overall drivability. That said, the NP435 is way less expensive than the ZF5, both as a used or rebuilt option, and its durability is legendary.

Now the T18 and T19 from BorgWarner are similar to the NP435. They’re both four speeds and they’re rugged and great for low-end work. The T18 has a granny low first gear around 6.32 to 1, but like the NP435, they lack an overdrive, so they fall short on fuel efficiency and drivability compared to the ZF5. Maybe the closest comparison is the M5OD. It’s a lighter-duty 5-speed used in Ford trucks from the late ’80s to the early 2000s. While it’s compact and great for light-duty applications, it doesn’t really handle high torque like the ZF5 does. That makes it less suitable for heavy hauling and off-roading or performance. It’s easier to find and less expensive, though, so if you don’t need the high torque capability of the ZF5, it’s probably a good option.

Now let’s touch on the NV4500. That’s the New Venture Gear. It’s a strong competitor with a low first gear and fifth gear overdrive, but it’s often seen in GM and Dodge trucks. It’s comparable to the ZF5 in durability and versatility, but it requires a custom adapter to fit a Ford engine, which increases cost and complexity, and it’s also not a Ford option. So if that’s important to you, an NV4500 might not be the best choice.

So the TREMEC TKO 600, it’s a performance-oriented 5-speed. It’s ideal for muscle truck builds where street feel and smooth shifting matter the most. However, it’s often more expensive by a fair bit than the ZF5, and its gear ratios are geared more toward performance driving than towing or off-roading. But if you’re looking for the meanest street/strip transmission and cost isn’t a concern, this is probably your go-to. If, however, you want your truck to feel like a truck, then you should stick with the ZF5.

And finally, we’ve got the TREMEC TR4050. It’s a modern option. The TR4050 offers a synchronized reverse and newer tech, but at $4,000 to $5,000, it’s a big investment. If you want a modern transmission with heavy-duty capabilities and you have the budget, it’s a strong choice. But the ZF5 is way more cost-effective and it’s way easier to find.

Okay, so let’s bring it all together and wrap it up. When it comes to finding the right transmission for your truck, the ZF5 has a lot going for it. It balances durability, versatility, and affordability for the most part, making it a top choice for Ford truck swaps. With five speeds, including that crucial overdrive gear, the ZF5 is an ideal transmission for those needing both low-end workhorse torque and want to cruise smoothly on the highway. One of the ZF5’s major advantages is its flexibility in configuration. There are six different mounting options when considering the three bell housing patterns: small block, big block, and diesel, and the two drivetrain configurations: 4×2 and 4×4. This makes the ZF5 a versatile choice for a range of builds, and it fits all those engines like the Windsor, the big blocks, and the IDI diesel. If you’re building a truck and need a tough, reliable manual transmission, odds are there’s a ZF5 that’ll bolt right up if it’s a Ford truck and as long as you can find it.

As I said before, for my own project, I’m strongly considering a ZF5 because it can handle the torque of a four-way stroker while not bringing an RPM that isn’t screaming on the highway. That said, the TKO600 has been on my radar too, whispering in my ear, mostly because of the street feel and the reputation it has for smoother shifts. It’s a choice that comes down to price and what kind of driving experience you want. The ZF5 will give you the toughness and reliability I’m looking for, and it’s generally easier to find and cheaper to rebuild. But if performance and that crisp street feel are top priorities, the TKO600 is a strong contender, even if it does cost a bit more. I’m still undecided, to be honest. You know, I like the idea of the nice, you know, that a truck is a truck and should shift like a truck, but man, that street/strip Windsor engine is kind of calling my name. Let me know in the comments what you think.

So that’s it, guys. Everything that I know or pretend to know about the ZF Friedrichshafen. But I like ZF. And that’s it, guys. That’s everything that I know or pretend to know about the Friedrichshafen ZF5, S542, and S547 5-speed manual transmissions with overdrive. Guys, as I always ask, if you learned something today, you found the content interesting, give me a like, give me a subscribe, go grab a cool hat, help me out. I really appreciate it. As always, thanks again so much for watching, guys, and we will see you next time. Take her away, getting things to shine that she’s considered divine. Thanks again for watching. We will see you next time. Thanks again for watching. We’ll see you next time.

Hey folks, Ed here from Bullnose Garage. Today, we’re diving into the ZF5 transmission, the 5-speed manual gearbox that might just be the perfect fit for your Ford truck. From the late ’80s to the late ’90s, these transmissions were the workhorses that helped Ford trucks tackle everything from daily drives to heavy towing. Whether you’re considering a swap or a rebuild, you’re about to get the inside scoop.

ZF5 Transmission Overview

Manufactured by ZF Friedrichshafen AG, the ZF5 transmission came in two main versions: the S5-42 and the S5-47. The S5-42 was the original model, offering up to 420 lb-ft of torque, while the S5-47 came later with a beefier 470 lb-ft torque capacity. Both models are known for their durability, making them a popular choice for Ford enthusiasts looking to upgrade from older four-speed gearboxes.

Specifications

The ZF5 is a 5-speed manual transmission with overdrive, all forward gears synchronized for smoother shifting. Here are the gear ratios for both versions:

  • First: 5.72:1
  • Second: 2.94:1
  • Third: 1.61:1
  • Fourth: 1:1 (Direct Drive)
  • Fifth: 0.76:1 (Overdrive)
  • Reverse: 5.24:1

Made of aluminum for strength and heat dissipation, it weighs about 135 pounds without fluid. This compact design makes it fit well in various Ford models, whether you’re dealing with a 4×2 or a 4×4 setup.

Driving Experience

Driving a ZF5 is all about the mechanical shift feel. If you’re accustomed to lighter-duty transmissions, get ready for a more deliberate gear engagement. Sure, it might require a bit more effort than something like a TREMEC TKO, but that notchiness gives you a real sense of connection to your truck.

Compatibility and Options

When it comes to engine compatibility, the ZF5 pairs with a range of Ford engines, including the Windsor 5.0L and 5.8L, the big block 7.5L, and even the 7.3L Power Stroke diesel. Note that the 4×4 and 4×2 versions are not interchangeable due to differences in output shafts and tail housings.

Choosing the Right Setup

With three different bell housing patterns (small block, big block, and diesel) and two drivetrain configurations (4×2 and 4×4), there are six possible setups for installing a ZF5. Make sure you pick the right one for your truck.

Identifying and Acquiring a ZF5

When hunting for a ZF5, look for the ZF logo on the side of the case and the distinct crisscross rib design. Prices can vary widely, with used transmissions ranging from $400 to $1,200, and rebuilt units going for $1,500 to $3,000.

Rebuilding Considerations

Rebuilding a ZF5 isn’t for the faint of heart but can be manageable with the right tools and experience. Parts and kits can run you around $400 to $600, but if you’re new to transmission work, consider having a professional handle the rebuild.

Common Issues and Upgrades

The ZF5 is known for its reliability, but like any transmission, it has its quirks. Worn shift forks and synchros are common issues, so keep an ear out for grinding noises that might indicate input shaft bearing wear.

For upgrades, consider a heavy-duty clutch for higher torque handling, a short throw shifter for quicker shifts, and an external transmission cooler to keep things running smoothly.

Comparing the ZF5 with Other Options

If you’re eyeing a ZF5 for a swap, here’s how it stacks up against other transmissions:

  • NP435: Great for off-roading but lacks overdrive.
  • M5OD: Compact and less expensive but not as robust.
  • NV4500: Comparable in durability but needs a custom adapter for Ford engines.
  • TREMEC TKO 600: More expensive with smoother shifts but less suited for towing.
  • TR4050: Modern but pricey.

Conclusion

The ZF5 transmission offers a solid balance of durability, versatility, and affordability, making it a top choice for Ford truck builds. Whether you’re after that tough manual shift feel or need a reliable gearbox for towing and highway cruising, the ZF5 has you covered. Let me know what you think in the comments, and if you’ve got any ZF5 stories, I’d love to hear them.

And as always, if you learned something today and want to support the channel, don’t forget to like, subscribe, and maybe snag yourself some Bullnose merch. Until next time, keep those trucks rolling!


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np435 Video

Published on August 27, 2024

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Show Transcript

Howdy folks, Ed here. Welcome back to Bullnose Garage. Today I’m actually out in my bun, driving around, so forgive the bumps and rattles and, you know, some of the noises that happen with an older truck. Today I’m here to talk about the NP435 transmission, which is this puppy right here. That’s what’s in my truck. It is a solid workhorse of a transmission and, uh, it’s certainly worth your consideration if you want to do a, uh, a swap or if you’ve already got one you want to do a rebuild. Uh, it’s probably worth your time. I’m going to get into exactly what everything is, how it works, uh, what all the stats are, that kind of stuff. Keep in mind, uh, this video is Bullnose-centric because it’s Bullnose Garage. So while I know, uh, that the NP435 was used in other vehicles like, um, you know, basically all kinds of vehicles across the board, uh, what I’m going to be focusing on are the Bullnose vehicles, the Fords. So you’re going to see some information in the video that is specific, uh, to the Ford versions. So that’s because I’m a Ford guy, you know, that’s how it works. So while I pop up onto the interstate here and let this engine scream for mercy as it goes into the high fourth gear on the transmission because there’s no overdrive, let’s, uh, go ahead and get into it.

Hello, the NP435. This manual gearbox isn’t just a transmission; it’s a piece of engineering that stood the test of time. Known for its durability and versatility, whether you’re restoring a classic or just curious about what’s under the hood, this guide will walk you through everything you need to know about the NP435, from its gear ratios and shift pattern to the engines it pairs with and how to keep it running smoothly. The NP435 is a four-speed manual gearbox designed with one goal in mind: durability. Built by New Process Gear, a name synonymous with heavy duty, this transmission has been a workhorse in Ford’s lineup since the 1960s. It was a natural fit for the Bullnose trucks and Broncos of the 1980s, providing the kind of robust performance that these vehicles are known for.

Now, what makes the NP435 particularly interesting is its gear setup. You’ve got four forward gears, but they’re not all synchronized. Second through fourth gears are synchronized, making for smooth shifts during regular driving. The first gear, often called the granny gear, and reverse, they’re not synchronized. So if you’re trying to pop into first while still rolling, you’re in for a bit of a grind, literally. But that’s by design because first gear is really meant for when you need serious torque to get moving, especially with a heavy load. So let’s talk gear ratios. The NP435 is known for its particularly low first gear, which is what gives it that reputation as a workhorse. In most Ford applications, you’ll find the following ratios: first gear 6.69 to 1, second gear 3.34 to 1, third gear 1.66 to 1, fourth gear 1 to 1, or direct drive, and reverse 8.26 to 1. There’s also a version with a slightly less extreme first gear at 4.85 to 1, but the low ratio version is what you’ll most commonly find in these Bullnose trucks. That first gear at 6.69 to 1 isn’t something you’d use in everyday driving unless your everyday involves towing a tractor out of a ditch or crawling over boulders. It’s all about giving you the torque to move heavy loads or navigate through terrain with confidence.

The shift pattern on this transmission is pretty straightforward. Here’s how it’s laid out: first gear is up and to the left, second is down to the left, third is straight up in the middle, fourth is straight down in the middle, and reverse, that’s far right and down. Now this pattern is practical, especially for a transmission designed to handle tough jobs. First gear is intentionally out of the way so you don’t accidentally engage it when you’re moving through the more commonly used gears. Moving on to the physical aspects of the NP435, this transmission is built like a tank. The case is made of cast iron, which gives it that characteristic durability but also adds some serious heft. At around 130 lbs, this isn’t the kind of transmission you casually toss around the garage. It’s hefty for a reason; it’s built to withstand the kind of stress that comes with heavy duty use. For the four version, the input shaft, which connects to your engine, has a diameter of 1 and 1/16 in with 10 splines. You’ll also notice a power takeoff or PTO port on the passenger side of the case. This cast iron construction and solid internals are part of why the NP435 has such a loyal following. It’s not flashy, but it’s the kind of component that you can rely on when the going gets tough.

So what can you bolt this transmission up to? The NP435 is versatile, fitting a range of engines that you typically find in Bullnose Ford trucks and Broncos. Whether you’re running the venerable Ford 300 inline 6 or one of the V8s like the 302, 351 Windsor, 400, or even the big 460, the NP435 has you covered. This flexibility made it a popular choice in a wide range of Ford trucks, from daily drivers to heavy duty workhorses. When it comes to fluids, the NP435 calls for SAE 50 weight oil or 80W90 gear oil. You might be tempted to use modern synthetic oils, and that’s fine, but make sure they’re compatible with the brass synchronizers inside the transmission. These old school gearboxes weren’t designed with synthetic fluids in mind, so using the wrong type can cause more harm than good. The transmission holds about 4.5 quarts, and it’s wise to change it every 30,000 to 50,000 miles, especially if you’re working the truck hard. The NP435 typically pairs with the mechanical clutch linkage in these trucks, which is straightforward and reliable. Depending on your specific setup, the clutch diameter usually hovers around 11 in, but there’s some variation depending on the engine and vehicle configuration.

When it comes to transfer cases, the NP435 is highly compatible with several options, making it a favorite among those building serious off-roaders or towing rigs. You’ve got the NP205, a gear-driven, highly durable transfer case that’s pretty much bulletproof. Then there’s the NP28, which is chain-driven and a bit lighter but still solid for most uses. The Borg Warner 1345 is also another option, reliable, chain-driven, and well-suited to off-road adventures. This compatibility with multiple transfer cases makes the NP435 a versatile option, whether you’re building a truck for the trail or the highway. Now cooling, unlike modern transmissions that might have dedicated cooling systems, the NP435 keeps it simple. It relies on air cooling, with a cast iron case acting as a heat sink to dissipate the warmth generated during operation. For most driving conditions, this setup works fine. However, if you’re planning on running it hard, whether that’s towing heavy loads or spending long hours off-road, make sure the transmission gets plenty of airflow. Overheating isn’t a common issue, but it’s something to be mindful of in extreme conditions.

Speaking of running hard, the NP435 can handle up to 450 ft-lbs of torque. That’s a significant amount, and it’s more than enough for the engines it typically pairs with. Whether you’re hauling, towing, or off-roading, this transmission is built to take the stress without breaking a sweat. Driving with the NP435 is an experience that feels more mechanical, more connected to the truck. Low first gear, often called granny gear, is great for when you need to get a heavy load moving or navigate tough terrain, but in everyday driving, most people start in second gear. The shifts are deliberate; there’s no rushing this transmission, and that’s part of its charm. On the highway, the direct drive fourth gear allows you to cruise comfortably, although the RPMs are higher than what you’d see with modern overdrive transmissions. But that’s the trade-off: you get strength and simplicity, but not necessarily the refinement of newer gearboxes. The NP435 shines in situations where durability and reliability are more important than smoothness. It’s excellent for off-road driving, towing, and any situation where you need to trust your transmission to get the job done.

When it comes to keeping your NP435 in good shape, regular maintenance, as usual, is key. Fluid changes are a must, especially if you’re putting the transmission through its paces. Luckily, routine service like this is straightforward, although the weight and bulk of the NP435 can make more in-depth work a bit challenging. Rebuilding the NP435 isn’t overly complicated compared to other transmissions, but it does require some mechanical know-how and the right tools. A full rebuild kit will set you back somewhere between $400 and $700, depending on the quality of the parts. Uh, if you need to replace major components or if the transmission is in particularly rough shape, a professional rebuild might be in order, and that could run you anywhere from $1,500 to $2,500. Given the longevity of this transmission, though, it could be a solid investment. The NP435 is renowned for its durability; with proper maintenance, this transmission can easily last over 200,000 miles. It’s a workhorse designed to handle tough conditions, whether that’s off-road, towing, or just the rigors of daily driving. But like any mechanical component, it does have its potential issues. Synchronizers in second through fourth gear can wear over time, especially if the transmission hasn’t been well-maintained. Bearings can also wear out, particularly if the fluid hasn’t been changed regularly. And if you’re doing a lot of heavy off-roading, the input shaft might show signs of wear sooner than expected. Despite these potential issues, the NP435’s reputation for reliability is well-earned. It’s built to last, and with a little care, it will.

The NP435 has been around since the 1960s, making it one of the more enduring designs in heavy-duty transmissions. Ford used it extensively across its truck lineup, from the F100 to the F350 and even in the Broncos. Here’s a quick rundown of where you might find one: at the Ford F100 from 1966 to 1983, the Ford F-150 from 1975 to 1986, the Ford F250 from 1966 to 1987, the Ford F350 from 1966 to 1987, and the Ford Bronco from 1966 to 1977. The NP435 was favored for its ability to handle the demands of these trucks, whether that was for work, off-road, or just reliable daily driving. And thanks to its popularity and long production run, the NP435 enjoys pretty strong aftermarket support. Whether you’re looking for a rebuild kit, replacement parts, or performance upgrades, there is no shortage of options. Popular modifications include upgrading the bearings, altering gear ratios for specific applications, and modifying the shifter for a shorter throw, especially useful in off-road setups. And this transmission might not have the glamour of modern units, but its reliability and the wealth of available parts and upgrades make it a favorite among enthusiasts.

So that all sounds great. The NP435 is strong, it’s reliable, it’s heavy-duty, and it can handle pretty much whatever you throw at it. And, uh, I’m pulling right out and putting in something different. Ed, Ed, why do you do this? You’re doing this to your 3006, and now you’re doing it to your NP435 too. Why do you keep changing things? Why do you keep pulling the most reliable components out of your truck? Well, to start with, the NP435 is a four-speed with a really low first gear. Now that’s great for heavy-duty tasks, but it can feel a bit clunky and unnecessary on the street, and I’m building a street truck. And I always start off in second gear and can count on one hand the times I’ve used first gear in a real-world situation. The shifts are heavy, and there’s no synchro in first, which means I’ve got to double clutch if I want to drop down into first while rolling. Now for some folks, that’s part of the charm. There’s a raw mechanical feel that reminds you that you’re driving something built to last. But if talking about refinement for a street queen is what my truck will be, the NP435 leaves a bit to be desired. The shifts are more of a workout compared to modern transmissions, and you’re going to feel every bit of that ruggedness in your hands. It’s not the smoothest operator, and on the highway, that missing fifth gear means my Windsor is going to be revving higher than I’m going to like. It gets the job done, but it’s not what I would call a relaxing drive.

So my choice? The ZF5 is a 5-speed manual, and that extra gear makes a world of difference when you’re just out for a drive. For starters, the ZF5 is a more refined transmission all around. It’s got synchronized gears across the board, which means shifts are smoother and easier, even in first. Everything about the ZF5 feels more polished and suited to street driving. The gear ratios are more evenly spaced, which will give me better control over the power from my built 351 Windsor. And where the ZF5 really shines is that fifth gear. On the highway, it lets the engine settle into a nice, comfortable RPM, making for a quieter, more fuel-efficient drive. And you’ll notice the difference right away: less noise, less strain on the engine, and an overall smoother ride. So if, like me, you’re setting up your truck for street use and you want to enjoy those horses without feeling like you’re in a tug of war with the gearbox, I’d say the ZF5 is the way to go. It’s smoother, quieter, and just more enjoyable for everyday driving. The NP435 has its charm, no doubt, but for a refined street experience, the ZF5 will make the truck a joy to drive, whether I’m cruising around town or hitting the highway.

All that said, the NP435 isn’t just a transmission; it’s a testament to durable, no-nonsense engineering. While it might lack the smoothness and refinement of more modern gearboxes, that strength and reliability more than make up for it. Whether you’re restoring a classic Bullnose Ford or just need a transmission you can count on, the NP435 is a solid choice, and it’s built to last. So as you guys can see and probably hear, I’m out here on the interstate going about 65 mph, and that’s about as fast as I can get this rig to go using the, uh, NP435 and my inline 6. And at 65, I’m in fourth gear, spinning about 26 or 2700 RPM, so it’s pretty high. It’d be nice to have an overdrive.

All right, guys, well that’s the NP435, everything that I know or pretend to know about this solid workhorse of a transmission. Hopefully, you learned something; that’s always my goal in all my videos is to, uh, impart knowledge, take the stuff that I’ve learned, stuff that I’ve researched, and pass it on to folks, uh, to maybe help them out a little bit. So you know, now’s the time that I ask, if you really want to support the channel, I’d appreciate a like, a subscribe, uh, drop a comment down below. Hey, if you really want to support me and get some cool stuff, check out my merch store. I’ve got a lot of really cool designs on there that I’m really happy with, you know, uh, especially get here if you, uh, like a little bit of granny gear. Yeah, get your granny on. Was that creepy? I feel like that was creepy. All right, guys, if you have any questions, comments, concerns, gripes, internet ramblings, stick them below. Thanks again for watching, guys. Oh, and by the way, that link is bullnosegarage.com merch. Get your granny on. Thanks again for watching, guys. We will see you next time. Oh.

Welcome back to Bullnose Garage, folks! Today, we’re diving into a piece of mechanical history that’s been pulling its weight in Ford trucks for decades—the NP435 4-speed transmission. This isn’t your run-of-the-mill gearbox; it’s a rugged workhorse that’s as tough as nails and has stood the test of time. Whether you’re knee-deep in a restoration project, contemplating a transmission swap, or just curious about what makes this beast tick, you’re in the right place.

What is the NP435?

The NP435 is a four-speed manual transmission that was designed with one primary goal in mind: durability. Built by New Process Gear, this gearbox has been a staple in Ford’s lineup since the 1960s. It’s a natural fit for the Bullnose trucks and Broncos of the 1980s, known for their robust performance and no-nonsense engineering.

Gear Ratios and Shift Pattern

Let’s talk numbers. The NP435 sports gear ratios designed to maximize torque, especially in first gear. In most Ford applications, you’ll find a first gear ratio of 6.69 to 1, which is fantastic if you’re looking to pull a house off its foundation. Second gear is at 3.34 to 1, third at 1.66 to 1, and fourth gear is a 1 to 1 direct drive. Reverse comes in at a steep 8.26 to 1. This setup is perfect for heavy-duty tasks, but it might feel a bit out of place on your daily commute.

The shift pattern is pretty straightforward. First gear is up and to the left, second is down to the left, third is straight up in the middle, fourth is straight down in the middle, and reverse is far right and down. It’s practical and keeps you from accidentally hitting that granny gear when you really don’t want to.

Physical Characteristics

If you’re thinking of getting yourself one of these, be prepared for some heavy lifting. The NP435 is built like a tank, with a cast iron case that adds up to a hefty 130 lbs. This weight isn’t just for show; it’s what gives the transmission its legendary durability. The input shaft measures 1 and 1/16 inches in diameter with 10 splines, and there’s a Power Take-Off (PTO) port on the passenger side for those extra accessories.

Engine and Transfer Case Compatibility

One of the things that makes the NP435 so versatile is its compatibility with a range of engines. Whether you’re running a Ford 300 inline 6, or a V8 like the 302, 351 Windsor, 400, or the big 460, this transmission fits right in. As for transfer cases, the NP435 plays well with the bulletproof NP205, the chain-driven NP208, and the reliable Borg Warner 1345.

Maintenance and Potential Issues

Keeping the NP435 in working order isn’t too difficult. It takes about 4.5 quarts of SAE 50 weight oil or 80W90 gear oil, and it’s wise to change it every 30,000 to 50,000 miles. While it’s a tough nut, it’s not indestructible. Synchronizers in second through fourth gear can wear over time, especially if the transmission hasn’t been well-loved. Bearings can also wear out, and if you’re doing a lot of off-roading, the input shaft might show signs of wear sooner than expected.

Why I’m Swapping to the ZF5

Now, you might be wondering why I’m swapping this beast out for a ZF5. Well, while the NP435 is a champ at handling tough jobs, it’s not exactly the smoothest operator for street driving. The ZF5, with its extra gear and synchronized shifts, offers a more refined driving experience, especially on the highway where that missing fifth gear in the NP435 means higher RPMs and a noisier ride.

Final Thoughts

The NP435 might lack the smoothness of modern gearboxes, but its strength and reliability are hard to beat. It’s a solid choice for anyone restoring a classic Ford or needing a transmission that can take a beating. If you’re setting up for street use, though, consider something like the ZF5 for a smoother, quieter ride.

Alright, that’s the lowdown on the NP435. If you found this breakdown helpful, hit that like button, subscribe for more no-nonsense content, and drop a comment if you’ve got any burning questions. And hey, if you want to support the channel and look cool doing it, check out my merch store and get your “Granny Gear” on. Thanks for tuning in, and I’ll catch you next time!


Bullnose Garage at YouTube

If you want more specific information on Bullnose Ford Trucks, check out my YouTube Channel!

For more information on Bullnose Fords, you can check out the BullnoseFord SubReddit or Gary’s Garagemahal. Both are excellent resources.

As an Amazon Associate, I earn from qualifying purchases. If you see an Amazon link on my site, purchasing the item from Amazon using that link helps out the Channel.