ZF 5 SPEED X BRONCO DANA 20

Advance Adapter

Our 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 a 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 and adapter instructions.

Transfer Case

The adapter assembly will fit any 1966-77 Bronco Dana 20 transfer case. This adapter will only work with the “T” style shifter. Transfer cases with a “J” style linkage will require modifications to retain this linkage. This cast iron, gear driven case has a low range of 2.46:1 and a front output shaft on the driver’s side.

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. We now offer 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 Dana 18/20 / 716302
• RETAINER- D20 BEARING FOR BRONCO / 716223
• BRONCO TRANSFER CASE GSKT / 716513
• ATLAS II SNAP RING FOR INPUT RETAINER. USED ON OLDER UNITS / 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