So I have a dead E4OD
in my truck and have been planning on swapping to ZF5
for some time. Now that my hand is forced, it's moving forward.
I bought a ZF S5-42 from a junkyard over ebay for $350. It's an 88 model, and has the typical cracked / broken case. I figured i'd weld the case up, but it's too far gone.
So I got a S5-47 front case over at pirate. Figured I'd detail some of the differences in cases here for anyone caught in my position who has to mix/match cases in future.
The extension housing had a big crack around the upper 3/4 of the output shaft / flange. We welded it up at work, my buddy did a great job.
The two individual gear stacks fit the case fine. Need to reset preload, but there's no significant length changes from 42 to 47.
The shift selector shaft is different from 42 to 47. The pocket depths have changed from 42 to 47, this will require either cutting down the 42 shaft or getting a 47 shaft.
There's some ribbing changes from the 42 to the 47. The case around the shift tower moved up on the 47, which should increase the torque capability some.
The input shaft retainer is different on the two cases. The 42 has a press in retainer from the inside, the 47 is a 3-bolt affair. Lengths appear same.
The gearsets are different from 42 to 47, different ratios. Allegedly, the 42 has a nicer ratio set for towing. We'll see.
Drain plugs are different 42 to 47.
(I'll put the photos up as soon as I can get them downloaded.)
Anyone want to contribute more photos and measurements to complete this thread?