Ford ZF S5-47 Transmission

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Convert your Ford ZF S5-47 to an Allison

Transform Your Drive: Making the Switch to an Allison 1000PK Transmission

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Unleash the true potential of your Ford with a ZF S5-47 to Allison 1000PK transmission conversion. This upgrade replaces the venerable ZF 5-speed manual, renowned for its ruggedness but often seen as the limiting factor in power and torque capabilities, with the modern, silky-smooth, and heavy-duty Allison 1000PK 6-speed automatic. Not only does this conversion allow your truck to handle more power while providing exceptional towing capability and reliability, but it also introduces a new level of driving comfort and efficiency, especially for those long-haul journeys. Don’t just drive—experience the road like never before with the unparalleled performance and luxury that the Allison 1000PK transmission brings to your Ford.

ZF S5-47 Transmission: An Overview, Key Features, and Common Concerns

Overview of the ZF S5-47 Transmission

The ZF S5-47 is a renowned manual transmission designed and manufactured by ZF Friedrichshafen AG, a leading global technology company. Introduced in the 1990s, this five-speed manual transmission has become a trusted choice for Ford truck owners, known for its remarkable durability and high torque capacity. Specifically engineered for Ford trucks, including the F-250 and F-350 models, the S5-47 is frequently paired with Power Stroke diesel engines, forming a resilient and dependable powertrain combination. With its ability to endure harsh and demanding usage conditions, the S5-47 has solidified its place as a reliable solution for heavy towing and rigorous work tasks.

Featuring a fully synchronized gear set and a robust cast iron case, the S5-47 is constructed to deliver smooth and precise shifting that enhances both performance and driver control. Its well-engineered components and extensive use of tapered roller bearings are testament to its longevity and functionality. The transmission is designed with a range of gear ratios, ensuring it is proficient in towing heavy payloads while maintaining a comfortable and fuel-efficient cruising speed on the highway.

However, as automotive industry trends have shifted towards more gears and increasingly sophisticated automatic transmissions, the S5-47, while dependable, represents a past era of technology. It appeals to a certain type of driver—those who value the direct control and unambiguous nature of a classic, solid manual transmission. For these individuals, the S5-47 remains a cherished and reliable choice.

S5-47 Features

The S5-47 transmission is a stalwart designed for demanding Ford truck applications. Distinguished by its robustness and high torque capacity, here are some key features that make the S5-47 stand out:

  • High Torque Capacity: Designed for heavy-duty applications, the S5-47 is constructed to handle elevated levels of torque, making it perfect for towing and hauling substantial loads.
  • Fully Synchronized Gears: The S5-47 features fully synchronized gears, ensuring smooth and precise shifting under various operating conditions.
  • Durable Construction: With its rugged cast iron case and hard-wearing internal components, the S5-47 is designed to endure the stringent demands of heavy-duty truck use.
  • Wide Gear Ratio Spread: The S5-47 offers a diverse range of gear ratios, enabling robust towing capacity and fuel-efficient highway travel.
  • Adaptable to Aftermarket Upgrades: Its well-established reputation has led to a flourishing aftermarket for the S5-47, offering parts and upgrade options for enthusiasts seeking to further optimize the transmission’s performance.

In summary, the S5-47 is a rugged, reliable, and versatile manual transmission crafted to handle the intense demands of heavy-duty truck applications. Its features are designed to provide drivers with exceptional towing capacity and enduring performance across a broad spectrum of conditions.

S5-47 Common Issues and Signs of Failures

While the S5-47 transmission is celebrated for its strength and heavy-duty performance, like any mechanical component, it can have its issues. Here are some common problems associated with the S5-47 transmission, along with signs that it might be failing:

  • Gear Synchronizer Wear: Over time, the synchronizers, which enable smooth gear changes, can wear out, leading to grinding or hard shifting.
  • Bearing Failures: The bearings in the S5-47 may fail due to heavy loads or insufficient lubrication, resulting in noise and potential damage.
  • Input Shaft Wear: Heavy towing can put stress on the input shaft, leading to wear and potential failure.
  • Seal and Gasket Leaks: Over time, the seals and gaskets may degrade, leading to fluid leaks and possible internal damage.

Regular maintenance, including appropriate fluid changes and timely replacement of worn components, can significantly prolong the life of a S5-47 transmission and avert many of these issues.

When encountering any of these symptoms, it is advisable to consult with a professional mechanic or transmission specialist to diagnose and address the problem before it leads to a complete transmission failure.

Your Guide to Rebuilding, Replacing, and Upgrading to an Allison Transmission

Rebuild, Replace, Converting to an Allison

Convert to Allison

Converting to an Allison 1000PK Transmission

Transitioning from the ZF S5-47 manual transmission to an Allison 1000PK automatic transmission is an extensive procedure that requires meticulous planning, precision, the right set of tools, and a profound understanding of both transmission systems. This guide outlines the steps required for a successful conversion:

  1. Research and Planning

    • Assess the compatibility of the Allison 1000PK with your specific engine and vehicle framework.
    • Identify any specialized conversion kits or components that facilitate this specific transmission swap.
    • Prepare a comprehensive list of tools, parts, and any specialized equipment necessary for the conversion.
  2. Acquire Necessary Parts

    • Procure the Allison 1000PK transmission unit.
    • Obtain a compatible bell housing or an adapter plate to connect the Allison transmission to your engine.
    • Purchase the Transmission Control Module (TCM) compatible with the Allison 1000PK.
    • Obtain the necessary wiring harnesses, electrical connectors, and adapters for this conversion.
    • Ensure the acquisition of a transmission cooler that meets the Allison 1000PK’s specifications.
  3. Removal of S5-47 Transmission

    • Disconnect the vehicle's battery.
    • Drain the transmission fluid from the S5-47.
    • Detach the transmission linkage, driveshaft, and all relevant electrical or hydraulic connections.
    • Carefully remove the S5-47 transmission from the vehicle.
  4. Preparation and Modification

    • Inspect and, if necessary, modify the vehicle’s transmission tunnel to ensure adequate space for the Allison 1000PK.
    • Replace or adapt any incompatible motor mounts, crossmembers, or transmission supports to secure a stable fit.
  5. Install the Allison 1000PK

    • Using a transmission jack, cautiously position and align the Allison 1000PK to the engine, verifying correct fitment with the bell housing or adapter plate.
    • Secure all connections, including mechanical linkages or hydraulic lines, as required.
  6. Electronics and Wiring

    • Install the TCM in a strategic, secure location, minimizing exposure to external elements.
    • Connect the wiring harness meticulously, ensuring all connectors are securely fastened and safeguarded from potential wear or damage.
    • Integrate the Allison's electronic components seamlessly with the vehicle’s existing electrical system, confirming proper communication between the TCM and engine control unit (ECU).
  7. Cooling System Installation

    • Install the transmission cooler in a location that allows for effective and efficient cooling.
    • Connect the cooling lines between the Allison 1000PK and the chosen cooler, ensuring a leak-free and secure connection.
  8. Drive Shaft and Final Connections

    • If necessary, adjust the existing driveshaft's length or consider a custom-made alternative for compatibility with the new transmission setup.
    • Install the driveshaft, ensuring proper alignment and secure connections at both ends.
  9. Fluids and Testing

    • Fill the Allison 1000PK transmission with the manufacturer-recommended transmission fluid.
    • Reconnect the vehicle's battery.
    • Start the vehicle, testing all gear positions for proper function and response.
    • Conduct a thorough test drive to confirm smooth operation of the transmission and appropriate behavior of the TCM.
  10. Final Adjustments

    • After the test drive, inspect the entire system for any leaks, abnormal noises, or inconsistencies.
    • If necessary, make recalibrations or adjustments to linkages, electrical components, or other related parts to optimize operation.

Documentation and Compliance:

  • Keep detailed records of all modifications, part replacements, and adjustments for future reference and potential resale purposes.
  • Always consult with local and regional regulations to ensure that your conversion complies with all safety, emissions, and other relevant legal standards.

Given the complexity of such a conversion, it is essential to engage with experienced professionals, particularly those familiar with transmission swaps between different brands or models. When executed accurately, this conversion can harness the reliability and efficiency of the Allison 1000PK, significantly enhancing your vehicle's overall performance and driving experience.

ZF S5-47 Rebuild

Rebuilding the Ford ZF S5-47 Transmission: A Comprehensive Guide

Rebuilding the ZF S5-47 manual transmission is a detailed and technical process that necessitates a deep understanding of transmission components, mechanical aptitude, and the proper set of tools. This guide outlines the steps required for a successful rebuild:

  1. Preparation and Research

    • Acquire the service manual for the ZF S5-47 transmission to familiarize yourself with its internal components and specifications.
    • Prepare a clean and organized workspace for disassembling, inspecting, and rebuilding the transmission.
    • Make a detailed list of tools, parts, and any specialized equipment required for the rebuild.
  2. Disassembly

    • Drain the transmission fluid and remove the transmission from the vehicle.
    • Carefully disassemble the transmission components, organizing and labeling each part to aid reassembly.
    • Take detailed notes and photographs throughout the disassembly process to use as a reference during reassembly.
  3. Inspection and Cleaning

    • Thoroughly clean all disassembled components using an appropriate solvent and inspect them for wear or damage.
    • Identify and list all components that require replacement due to excessive wear or damage.
    • Inspect and measure clearances and tolerances according to the specifications in the service manual.
  4. Acquire Replacement Parts

    • Purchase all necessary replacement parts, including bearings, seals, gaskets, synchros, and gears, as per your inspection.
    • Ensure that all replacement parts are specific to the ZF S5-47 model and meet the manufacturer's specifications.
  5. Reassembly

    • Carefully reassemble the transmission, following the service manual and your notes and photographs from the disassembly stage.
    • Ensure all components are installed in their correct orientation and torqued to the specified values.
    • Install new seals, gaskets, and bearings during the reassembly process to ensure the longevity and reliability of the rebuild.
  6. Testing and Adjustment

    • Before installing the rebuilt transmission in the vehicle, rotate the input shaft manually to check for binding or abnormal noises.
    • Make any necessary adjustments to component clearances or tolerances as per the service manual specifications.
  7. Installation and Fluid Refill

    • Carefully install the rebuilt ZF S5-47 transmission back into the vehicle.
    • Refill the transmission with the manufacturer-recommended transmission fluid to the correct level.
  8. Road Testing

    • After installation, perform a comprehensive test drive under various conditions to confirm the transmission’s smooth and correct operation.
    • Monitor for any abnormal noises, vibrations, or shifting issues during the test drive.
  9. Final Adjustments and Inspection

    • After the test drive, inspect the entire system for any leaks, noises, or inconsistencies.
    • If necessary, make final adjustments to the linkages or components for optimal operation.


  • Keep a detailed record of all steps performed, components replaced, and adjustments made during the rebuild for future reference and potential resale purposes.
  • Store all receipts for parts purchased during the rebuild to validate the quality and origin of components used.

Rebuilding a ZF S5-47 transmission is a complex and rewarding endeavor that can breathe new life into your vehicle’s drivetrain. Due to the intricate nature of this project, it is highly recommended to seek guidance from a seasoned professional, especially if this is your first time rebuilding a transmission. When executed correctly, a rebuilt ZF S5-47 can offer many more miles of reliable and efficient service.

Replace 4R100

Replacing the Ford ZF S5-47 Transmission: A Comprehensive Guide

Replacing a ZF S5-47 manual transmission is a meticulous task that requires careful preparation, a solid understanding of mechanical systems, and the right set of tools. This guide outlines the steps required for a successful replacement:

  1. Research and Planning

    • Acquire the service manual for the ZF S5-47 transmission to familiarize yourself with its specifications and removal process.
    • Determine the compatibility of the replacement transmission with your vehicle’s engine and chassis.
    • Prepare a detailed list of tools, parts, and any specialized equipment required for the replacement.
  2. Acquire Replacement Transmission

    • Source a new or rebuilt ZF S5-47 transmission that meets the specifications for your vehicle.
    • Verify the quality and condition of the replacement transmission, ensuring it comes with a warranty if possible.
    • Obtain any additional parts that may be needed, such as a new clutch assembly, seals, or gaskets.
  3. Removal of Old Transmission

    • Disconnect the vehicle's battery.
    • Drain the transmission fluid from the existing ZF S5-47.
    • Unlink the transmission linkage, driveshaft, and any pertinent electrical or hydraulic connections.
    • Carefully extract the old ZF S5-47 transmission from the vehicle.
  4. Preparation for Installation

    • Clean and inspect the area where the new transmission will be installed, ensuring there are no obstructions or debris.
    • If replacing the clutch assembly, prepare the flywheel surface and install the new clutch components.
  5. Install the Replacement Transmission

    • Utilizing a transmission jack, carefully position and align the replacement ZF S5-47 to the engine, ensuring correct fitment.
    • Secure all connections, including any required mechanical linkages or hydraulic lines.
  6. Fluids and Testing

    • Refill the replacement ZF S5-47 transmission with the manufacturer-recommended transmission fluid.
    • Reconnect the vehicle's battery.
    • Initiate the vehicle, testing all gear positions for accurate function and response.
    • Perform a comprehensive test drive to confirm the transmission’s smooth operation.
  7. Final Adjustments and Inspection

    • Post-test drive, examine the entire system for any leaks, noises, or inconsistencies.
    • If necessary, make final adjustments to the linkages, electrical components, or other associated parts for optimal operation.

Documentation and Compliance:

  • Retain a record of the replacement process, part numbers, and any adjustments for future reference and potential resale purposes.
  • Keep all receipts and warranty documentation for the replacement transmission and any other new parts installed during the process.
  • Consult local and regional regulations to ensure your replacement adheres to all safety, emissions, and other pertinent legal guidelines.

Replacing a ZF S5-47 transmission is a significant undertaking that can restore your vehicle's performance and reliability. Due to the complexity of this task, it is advisable to consider professional assistance, especially if you have limited experience with transmission work. When executed correctly, a transmission replacement can provide a revitalized driving experience, enhancing your vehicle's overall function and longevity.

Benefits of converting to an Allison 1000PK Transmission

Converting to the Allison 1000PK transmission can offer a significant improvement in the performance, durability, and efficiency of a vehicle. Known for its use in a wide range of applications, from light-duty trucks to heavy-duty commercial vehicles, the Allison 1000PK is a trusted choice for many looking to upgrade their transmission system. Below are some key benefits of making the conversion:

Enhanced Durability and Reliability

Allison transmissions, including the 1000PK series, are renowned for their durability and longevity. They are designed to handle heavy loads and demanding conditions, reducing the likelihood of frequent repairs and breakdowns, which makes the Allison 1000PK a long-lasting solution.

Improved Towing and Hauling Capabilities

The Allison 1000PK provides superior torque and power handling, allowing for more efficient and safer towing and hauling. Whether you are pulling a large trailer, boat, or other heavy loads, this transmission can help your vehicle perform at its best under strenuous conditions.

Smooth and Adaptive Shifting

With its sophisticated control system and efficient design, the Allison 1000PK can contribute to better fuel economy. By optimizing shift points based on load, speed, and other factors, it helps the engine run in the most efficient range, potentially saving fuel over time.

Lower Maintenance Costs

The robust design and high-quality components used in the Allison 1000PK often result in lower maintenance costs over time. Its proven durability under various conditions can lead to fewer required repairs and service intervals, translating to long-term cost savings.

Versatility and Compatibility

The Allison 1000PK is designed to be compatible with a wide range of vehicles and applications. This makes it a versatile option for those looking to upgrade their transmission in various types of vehicles, from light trucks to commercial applications.

Resale Value

Installing a well-regarded and reliable transmission like the Allison 1000PK can increase the resale value of your vehicle. Buyers often appreciate the quality and dependability associated with Allison transmissions, which can make your vehicle more attractive on the resale market.

What's included in an Allison Conversion kit?

We provide everything you will need to get the swap done right

Duramax with Allison Transmission
    • Kit Includes
    • Transmission
      Torque Converter
      Wiring Harness
      Flex Plate adapter
      Transfer Case
      Mounting Kit
      Cooling Kit
      Digital Display
      Allison TCM
      CAC TCM
Allison 1000PK Transmission

Allison 1000PK Transmission

Upgrade your vehicle's capabilities with the esteemed Allison 1000PK Transmission. You have the option to either include this component in your kit purchase or use your own pre-acquired Allison 1000PK transmission. To cater to your needs, we also provide transmission rebuilding services. Explore a comprehensive selection of other Allison transmissions here that we can expertly convert.

How to determine the Right Torque Converter

Maximizing Performance: Using Tire Diameter and Gear Ratio Calculations to Choose the Ideal Torque Converter

How to determine the right torque converter


By converting your Ford's transmission to an Allison, you can expect improved durability, enhanced towing capability, better fuel efficiency, and smoother shifts, overall optimizing your vehicle's performance.

While many Ford vehicles can benefit from an Allison transmission conversion, it's best to consult with a specialist to ensure your specific model's compatibility.

Yes, with our t-case adapters, you can use your existing Ford transfer case in an Allison conversion.

The Allison 1000 series is a popular choice for Ford vehicles due to its reliability and performance. However, the best choice depends on your specific needs and vehicle model.

The conversion process involves removing your Ford's current transmission, fitting the Allison transmission with the necessary adapters, and installing it. The wiring harness, TCM, and other components are also adjusted accordingly.

Yes, an Allison transmission is designed to provide smoother shifts, greater durability, and improved fuel efficiency, all contributing to enhanced vehicle performance.

An Allison conversion kit typically includes components such as the transmission (if chosen), TCM, torque converter, wiring harness, adapters, and other necessary parts for the conversion.

You can choose to provide your own Allison transmission, or you can opt to include it with your conversion kit purchase.

While it's possible for experienced individuals to perform the conversion, it's generally recommended to seek professional help to ensure the job is done correctly and safely.

The conversion time can vary greatly depending on the vehicle and the specific conversion kit. On average, it might take a few days to complete.

An Allison conversion may affect your vehicle's warranty depending on the terms and conditions of your specific warranty agreement. We recommend checking with your warranty provider before proceeding with the conversion.

Should you encounter any problems post-conversion, we recommend contacting your conversion specialist for troubleshooting advice or potential service needs.

Yes, an Allison transmission from another vehicle can be used, provided it's compatible with your Ford model. Ensure to consult with your conversion specialist before proceeding.

Yes, we provide rebuilding services for Allison transmissions, ensuring your transmission operates at peak performance.

The cost can vary significantly depending on the specific Allison model, whether you're providing the transmission or purchasing it as part of the kit, and any additional services required. Please contact us directly for a more accurate estimate.

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