ZF 22 vs 24

robertf

Well-known member
Jan 22, 2006
4,781
358
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I'm putting together a better ZF to match the 4.6

Here are some of the differences I've found in the process of putting it together. I started with a run of the mill 4.0 D1 1043-010-747

I'm putting as many 4HP24 parts in there out of a 1043-030-069 from a 2004 D2


E and F clutch
same clutch packs
rear housing is different to accommodate governor on the mechanical ZF 4HP22

Freewheel clutch
Output shaft necks down on the 22, must use 22 output shaft to fit rear F clutch housing

C and D clutch
D clutch has 1 more clutch pack, finer teeth on clutches
C clutch is the same
1 way clutch is stronger on the 24

A and B clutch

A clutch is huge, 15mm longer. Major difference between the 22 and 24
B clutch has 1 more clutch pack, housing c clip location is machined different for extra clutch pack thickness

zf001.jpg

zf004.jpg

zf005.jpg

zf006.jpg

zf007.jpg

zf008.jpg

zf009.jpg

zf010.jpg

zf016.jpg

zf017.jpg

zf022.jpg
 

aliastel

Well-known member
Sep 27, 2009
942
0
Champaign, IL
Thought about doing this but decided that I'm just going to bolt in a 4HP24 as is and control it with a Compushift. Then I can adjust shift points at will and run dual shift modes. Have the option of replacing the trans when necessary with stock units as required.
 

robertf

Well-known member
Jan 22, 2006
4,781
358
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I thought about that. The compushift could be awesome, but I fear proprietary low volume production electronics that are essential to operating the vehicle.

I see that the 24 transmission mount looks almost identical to the 22 other than being skewed back 15mm. I haven't looked at the transfercase mount for a 24 equipped truck. Were you able to use stock mounts?
 

robertf

Well-known member
Jan 22, 2006
4,781
358
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no

the 24 case isn't machined for the 2 passages for the governor, and if it were you'd still need to swap parts out for the governor to fit.
 

robertf

Well-known member
Jan 22, 2006
4,781
358
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the last picture shows the governor on the right and the 24 tone ring on the left. The transmission control reads the outputshaft speed and toggles a hydraulic valve when its spinning fast enough. The governor is a set of mechanical weights and springs that open an internal valve when its going the right speed. You can see the extra 2 fluid passages on the back of the F clutch housing in the 5th and 6th pictures. The inlet is at the base, there is a group of 4 on the 22 and they are absent on the 24. Those line up with the valve body ports that are not drilled through on the 24 case.

I think if you left it out the transmission would overheat and slip at speeds above 50ish mph