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Ford Bronco ZF 5 Speed to D20 Transfer Case Adapter
We offer an adapter and shaft assembly to adapt the Bronco Dana 20 transfer case to the ZF 4wd 5 speed transmission.
Advance Adapter
The Ford ZF 5 speed adapter to the Bronco Dana 20 is 1.40" in length. The adapter material is 356 T-6 heat treated aluminum alloy.
The adapter kit includes:
- adapter plate
- special spud shaft with 31 internal spline
- shifter linkage bracket
- transfer case pivot bolt
- bearing retainer
- sealed bearing snap ring
- gaskets
- o-ring
- fastening hardware
- adapter instructions
Transfer Case
The adapter assembly will fit any 1966-77 Bronco Dana 20 transfer case. This cast iron, gear driven case has a low range of 2.46:1 and a front output shaft on the driver's side.
This adapter will only work with the "T" style shifter.
Transfer cases with a "J" style linkage will require modifications to retain this linkage.
Transmission
The kit is designed for exclusive use with the Ford ZF 5 speed 4wd manual transmission ( ZF S542 & S547). This heavy duty 5 speed is all aluminum with an integral bellhousing to the case. It can be easily identified by its diamond-shape casting ribs and a small 4-bolt top cover.
The S542 was used in Ford trucks 1987-94 and the S547 1995 to present. The ZF 5 speed has been used in full size Fords from 1987 to the current models.
These transmissions are now starting to show up in salvage yards, and we've been getting more requests for adapters to couple this 5 speed to the various transfer cases.
The kit we now offer is a kit that couples the ZF transmission to the Bronco Dana 20.
This aluminum adapter is 1.5" long and comes with a new spud shaft and alignment retainer.
The installation of this transmission will require the fabrication of a new crossmember and transfer case shifter linkage bracket.
The ZF 5 speed is a large transmission and, due to its size, driveline modifications and a body lift are required.
This transmission has either a 4.65:1 or 5.72:1 first gear, and a 23% overdrive which makes it an ideal transmission for on and off road capabilities.
Bill Of Materials
BEARING SEALED 307 / 716302
RETAINER- D20 BEARING FOR BRONCO / 716223
BRONCO TRANSFER CASE GSKT / 716513
SNAP RING / 716455
SHAFT- ZF TO BRONCO D20 SPUD / 52-4303
ADAPTER- JEEP TRANS TO BRONCO D20 / 51-9920
BOLT- SHOULDER 5/8 x 2 (1/2-13) / 715544B
BRACKET- LINK JEEP TRANS TO D20 / 715544
S.H.C.S. 3/8 -16 X 1-3/4 / 723729
H.H.C.S. 3/8 -16 X 1-1/2 gr. 5 zinc / 723723
5/8 FLAT WASHER SAE OD / 726207
O-RING BRONCO INDEX RETAINER / 716714
GASKET-N.P.208 TRANSFER CASE / 716517
H.H.C.S. 3/8 -16 X 1-1/4 (GR5) zinc / 723722
LOCK WASHER 3/8 ZINC / 723704
Your stock EB flywheel and clutch will work with the ZF.
A 6" X 7" hole in the tunnel cover is required.
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