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DRIVE TRAIN / MANUAL TRANSMISSION & ADAPTERS
 
ZF TRANSMISSION TO D20 ADAPTER KIT

The Ford ZF transmission is the best manual transmission available for your Early Bronco. This is a state of the art five speed transmission that shifts smoothly and has an excellent low gear 5.71:1 as well as overdrive .72:1. ZF transmissions will bolt right to your 302/5.0L or 351 Windsor/5.8L. BC Broncos has developed a complete install kit to bolt the ZF to your Dana 20 complete with cross member, hydraulic master and slave cylinder stainless steel flex line and clutch rod. You must use a ZF transmission from a 1988-1999 Ford 4X4 pickup with a small block engine (302/5.0 or 351/5.8). Your stock EB flywheel and clutch will work with the ZF too. The ZF installation does not require a body lift, only a 6" X 7" hole in the tunnel cover.

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, T 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
 
Transmission The kit is designed for exclusive use with the Ford ZF 5 speed manual transmission ( ZF S542 & S547). This heavy duty 5 speed is all aluminum with an integral bell housing to the case. It can be easily identified by it’s 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 1999.

ZF trans showing measurements

TIP: The ZF uses 3.2 qt's of Dextron ATF or MTF

Tcase and trans shifter hole location

 

11          11                            

 

Here is the ZF shifter 2,4,R

Here is the ZF shifter 1,3,5 gear with more than enough room near the dash.

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11       11

                                                                 Adapter only

                Install kit

 

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Part Number
                   PART            

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21-11100
ZF TO D20 ADAPTER COMPLETE KIT

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21-11200
ZF TO D20 ADAPTER

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21-11300
CROSS MEMBER

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21-24010
HYDRAULIC CLUTCH KIT

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21-21100
CLUTCH MASTER CYLINDER

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21-22000
CLUTCH SLAVE CYLINDER

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21-24000
STAINLESS STEEL CLUTCH LINE

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21-23000
CULTCH ROD

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85-00230
BACK UP LIGHT SWITCH
 
 
SHIFTER

 

When you buy a ZF make sure they give you the upper and lower shifter

If not it will cost you more, make sure you factor that into your deal.

ZF shifter

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Part Number
                   PART            

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21-40112
B. STOCK UPPER SHIFTER

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21--40113
C. SHIFTER KNOB

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21-40115
D. LOWER SHIFTER

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21-40121
E. LOWER SHIFTER DUST BOOT

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21-40123
F. DUST BOOT RETAINING RING

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21-40117
G. LOWER SHIFTER BUSHINGS (2 needed)

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21-40124
H. LOWER SHIFTER BOOT PLATE

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21-40118
H. LOWER SHIFTER PLATE GASKET

 

 

 
GEAR GAWKER

The Gear Gawker clear cover for the ZF, this is a great way to keep an eye on your fluid level but if you look close you can see if their are any metallic partials in the oil indicating a problem without taking the cover off, This is an easy way to check your ZF before you go to an event. But are they strong? These are made of 1/2 inch thick poly carbonate glass made for the view slits of armored vehicles. These covers will take a serious beating and hold up to temps over 600* without failing.

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Part Number
                   PART            

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21-30141
ZF LEFT  GEAR GAWKER CLEAR COVER

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21-30142
ZF RIGHT  GEAR GAWKER CLEAR COVER

 

 

 
NP 435 TO DANA 20 ADAPTER PLATE

The NP435 transmission is a popular swap for Early Broncos, revered for its reliability and great low gear. This precision machined adapter kit allows mating the NP435 to the Early Bronco Dana 20 transfer case, making the swap clean and easy. Note: This adapter requires an intermediate adapter (housing and shaft) from a 6 cylinder Bronco. You must provide this. BC Broncos sometimes has these on hand--call for pricing and availability.

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Part Number
                   PART            

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22-17041
435 ADAPTER
 

 

 
NP 435 / T18 TO DANA 20 ADAPTER

The NP435 transmission is a popular swap for Early Broncos, revered for its reliability and great low gear. This adapter kit allows mating the NP435 to the Early Bronco Dana 20 transfer case, making the swap clean and easy. This adapter DOES NOT require an intermediate housing and shaft  from a 6 cylinder Bronco. With this kit they cast the housing and the adapter as one piece so you do not need any used parts.

Advance Adapter The Ford NP435 & T18 adapter the Bronco Dana 20 is 7.50” in length. The adapter material is 356 T-6 heat treated aluminum alloy, and the adapter has a provision to retain the original early Bronco mount. The adapter kit includes an adapter housing, alignment retainer, snap ring, gaskets, seal, 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.
 
Transmission The kit is designed for exclusive use with the Ford NP435 & T18 4 speed transmissions, 2wd version with a 28 spline output shaft. The NP435 cast iron case length is 10.875” and has a aluminum top cover. It was used in Ford trucks from 1964-85. When using our adapter kit with the NP435 & replacing a 3 speed manual in a V8 early Bronco application, the transmission conversion will not require any drive line modifications.
 
The Ford T18 cast iron case length is 11.875” and has a cast iron top cover. It was used in Ford trucks from 1967-84. The T18 is 1” longer than the NP435, requiring new drive shafts.

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Part Number
                   PART            

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22-17040
435 ADAPTER
 

 

 
NV 3550
Advance Adapter This adapter kit will allow you to adapt the Jeep NV3550 5 speed manual transmission to the Bronco Dana 20 transfer case. The adapter is 1.40” in length and is made from strong 356 T-6 heat treated aluminum alloy. The adapter kit includes an adapter spacer, spud shaft, shifter bracket spacers, transfer case shifter linkage bracket for T-style shifter, pivot bolt, bearing retainer, bearing, snap ring, gaskets, seal, o-ring, fastening hardware and adapter instructions.
Note: This adapter assembly and transfer case shifter bracket only works with the Bronco Dana 20 transfer cases with the “T” style shifter!!!
 
Transfer Case The adapter assembly will fit the 1966-77 Bronco Dana 20 transfer case. This cast iron, gear driven case and has a decent low range Similar to the Jeep version except that the front output shaft on the driver’s side.
1966-72 Bronco Dana 20 featured a 2.46:1 low range and a “T” style shifter.
1973-77 Bronco Dana 20 featured a 2.38:1 low range and a “J” style shifter.
 
Transmission The NV3550 is the newest 5 speed transmission from Jeep and found in the 2000-2005 4.0L Wrangler TJ and Liberty. Similar to the AX15, the overall length of the NV3550 is 24.00”, has a removable bell housing. The differences are&null

1  2

                                                           The shifter comes out just off to the side of where the stock 4X4 shifter goes.

11               11

                                    Adapter only

                      Install kit
 

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Part Number
                   PART            

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22-17050
NV 3550 ADAPTER ONLY

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22-17052
NV 3550 CROSSMEMBER KIT

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21-17051
COMPLETE INSTALL KIT WITH TRANSMISSION
 

 

 
NV 4500
Advance Adapter The Dodge NV4500 adapter to the Bronco Dana 20 is 1.00” in length. And the overall length of this transmission and adapter is 19.50”. Adapter material is 356 T6 heat treated aluminum alloy. The adapter kit includes a Bronco Dana 20 adapter plate, spud shaft with 23 internal spline, t-case shifter bracket, bearing retainer, bearing, snap ring, gaskets, seal, 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.
 
Transmission The adapter kit is designed for exclusive use with the Dodge 4WD NV4500 transmission with a 23 spline output shaft.

4   5

High gear                                                                        Low gear

6 

11              11

                              Adapter only

              Install kit
 

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Part Number
                   PART            

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22-17061
NV 4500 ADAPTER KIT ONLY (23 SPLINE)

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22-17062
NV 4500 ADAPTER KIT ONLY (29 SPLINE)

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22-17063
NV 4500 CROSS MEMBER KIT
 

 

 
FLYWHEEL

Here are new flywheels we have two types a 50oz balance and 28oz balance if you use the wrong flywheel or damper you will have bad vibrations in your motor. To make sure your starter will engage you need a flywheel with 164 teeth
(we only carry the 164 tooth)

Here is the info from Ford
For a 302 1968-1980 the imbalance is 28oz
For a 302 1981-2001 the imbalance is 50oz

For ALL 351W 1969-1997 the imbalance is 28oz

FLYWHEEL

 

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Part Number
                   PART            

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16-00210
V-8 FLYWHEEL 50OZ

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16-00110
V-8 FLYWHEEL 28OZ

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16-00030
FLYWHEEL BOLT KIT
 

 

 
CLUTCH

All new clutch not remanufactured. please let us know what size clutch bolts you have

new clutch kit

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Part Number
                   PART            

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16-00010
Clutch 289-302-351W

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16-00020
Clutch 5.0L

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16-00032
Clutch bolt set 5/16

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16-00031
Clutch bolt set 3/8

 

 
CLUTCH LINKAGE

Their are many parts for a stock clutch, to get the clutch to operate smoothly you need all of these parts.

clutch parts

A: Is for engine blocks that don't have a threaded hole to bolt on linkage

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Part Number                    PART            

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16-00041
A. CLUTCH EQULIZER ENGINE BRACKET FOR  5.0L OR LATER 351w/5.8

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67-55300
B. CLUTCH ROD BOOT

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67-55210
C. CLUTCH FORK BOOT V-8

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67-55220
D. CLUTCH FORK BOOT I-6

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16-00040
E. EQULIZER BAR REBUILD AND SEAL KIT

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16-00050
F. CLUTCH ROD BUSHING set of 2

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67-52120
G. CLUTCH PEDAL BUMPER

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67-52110
H. CLUTCH PEDAL PAD

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67-52111
I. CLUTCH PEDAL PAD BRONCO SCRIPT

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16-00060
J. CLUTCH PEDAL PIVOT BUSHING (2 needed)

 



BC Broncos -110 Business Drive / PO BOX 69 Ingram, TX 78025
Tech line: (830) 367-1300 Order line: (888) 304-2945 <Fax: (830) 367-1304