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Old 08-27-2011, 01:56 AM   #1 (permalink)
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NV4500 vs ZF5

First to give you some background so you know what I'm dealing with, I am an owner of 2 older ford pickups both with a zf5 in them, one is 2wd and the other 4wd, love both the trucks. But i have just recently purchased a beat up 96 3500 4x4 dually with the intentions of fixing it up nice and using it for work and play. The truck had a lot wrong with it when i bought it but i was able to drive it home. Once i had gotten all of the major mechanical stuff fixed such as the brakes, steering, oil leak, small stuff like that to make it a good runner. I drove it still looking like a beat up old pos but it ran and drove excellent. So i turned up the pump as far as i dare go with everything being stock. everything worked awesome for about a month then the counter shaft 3rd gear broke 3 teeth right off the gear.
Now my question is this, i could buy all the stuff and rebuild this trans myself no problem, i have done it once before. But on the other hand i do like the way a zf5 is built better. And i would consider myself more familiar with them seeing as i have 2 trucks already both with that transmission. And i have rebuilt these as well. I honestly think its a better transmission and i want to put one behind my cummins, but what do i have to do to make it work other than the adapter plate? do i need do fab a cross member? do i have to use a ford transfer case? do i have to get new drive shafts? can i used the dodge transfer case? just a lot of questions i was hoping someone who has done this could tell me what the best route to go is. attached i have a pic of the truck, the broken counter shaft, and the zf5 what i want to put in in, all pics i have taken in my shop. Any advice or help is greatly appriciated!

Last edited by Babagnoosh; 07-17-2012 at 02:22 PM.
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Old 08-29-2011, 08:43 PM   #2 (permalink)
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Has anyone on here delt with doing a convertion? will the ZF5 hold up to the tourque? whats the best route to go i need to get this truck fixed but i want it bullet proof.
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1996 4x4 3500 dually, NV4500 hardened gears, ceramic kevlar clutch, eaton tru-track diff, afc tuned, cut fuel plate, 330 injectors, 4K GSK, 60# valve springs, head studs, 17* of timing, S&B filter, twin turbos, 5" exhaust to 6" stacks, adj. OFV.
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Old 08-30-2011, 12:28 AM   #3 (permalink)
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I've heard of guys running them, but never heard how they held up. Somewhere there should be some torque info on them.
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Old 08-30-2011, 12:45 AM   #4 (permalink)
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ZF 5 Speed Transmission Specs
NV4500 Transmission Specs
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Old 08-30-2011, 01:32 AM   #5 (permalink)
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thanks, those links were very helpful i appreciate it
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1996 4x4 3500 dually, NV4500 hardened gears, ceramic kevlar clutch, eaton tru-track diff, afc tuned, cut fuel plate, 330 injectors, 4K GSK, 60# valve springs, head studs, 17* of timing, S&B filter, twin turbos, 5" exhaust to 6" stacks, adj. OFV.
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