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Thread: ZF6 Swap - Possible With BW44-46?

  1. Top Of Page | #1

    ZF6 Swap - Possible With BW44-46?

    Looking deeper into this ZF6 swap idea, I've come across a dilemma in the whole thing, specifically the 2003+ ZF6 and their 34 spline output shaft (or the 99-03 ZF6s with 31 spline).

    Being that the 68RFE is a 29 spline output, the BW44-46 is expecting that obviously.

    One option that comes to mind is swapping in a 29 spline output shaft from a GM ZF6.

    The other option is trying to modify the BW44-46 to accept a 34 spline shaft.

    Does anybody have experience with either of these options?


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  3. Top Of Page | #2
    Chrisn162001's Avatar

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    ZF6 Swap - Possible With BW44-46?

    Why not just swap a G56?

    I’ve only heard of using the ZF6 when swapping a Cummins into a Ford.

    Maybe source a Ford NP271 transfer case they are still driver-side drop.

    Unless you are trying to keep the e-shift transfer case.


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  5. Top Of Page | #3
    Chrisn162001's Avatar

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    Re: ZF6 Swap - Possible With BW44-46?

    I also thought electric shift t cases wouldn’t go into 4low when swapped into a manual trans.

    Something about ECU or DTCM has to see the truck is in neutral.


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  7. Top Of Page | #4

    Re: ZF6 Swap - Possible With BW44-46?

    I've heard the G56, albeit a nice trans in stock form, is not great for higher HP applications.

    If I were to stick to a stock Dodge trans, I'd go NV5600, but they too are not reliable unless they are built correctly.

    I want to keep the ESOF transfer case.

    I thought about using an NV273 case from a Ford too, but I'm not sure it would play nice with the front AAM axle disconnect on the newer RAMS since the BW44-46 is a partial clutch-based transfer case.


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  9. Top Of Page | #5
    CumminsForYa's Avatar

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    Re: ZF6 Swap - Possible With BW44-46?

    Look up SuperStick transmissions & Lazarsmith torque cages.

    G56 can hold plenty of power.

    '08 | G56 | Carli 3" | Carli Axle Truss | BDS Adjustable Traction Bars | BDS Steering Brace | Red-head Gearbox | Synergy HD Steering | Banks Cold Air Intake | Banks Intake Manifold | Steedspeed Exhaust Manifold | Grid Heater Delete | Fleece Cheetah Turbo | Fleece Fuel Filter Delete | Fass 165gph System | Fass Fuel Heater Disc | Fass Fuel Sump | EFI Live | Fuel Revolver Wheels | 35" BFG All-Terrains

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  11. Top Of Page | #6
    Chrisn162001's Avatar

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    ZF6 Swap - Possible With BW44-46?

    The clutch synchro unit in the 44-46 has nothing to do with the front axle.

    It’s what allows the transfer case to shift on the fly.

    Really neither the G56 NV5600 nor the ZF6 is gonna hold much past 750hp.

    The G56 can be built to hold more, and parts are available.

    The NV5600 hard parts are hard to come by, and there’s really nothing to improve 6th gear.

    Zf6, I haven’t seen many behind high hp trucks 7.3 and 6.0s weren’t know for making power.

    The Chevy guys making power prefer the Allison.

    I’ve replaced 1-2 synchros in a few, but that’s about it.

    The Chevy has some updates over the Ford version, something with the shifter and lube lines.

    I’d have to dig up my notes to be sure.

    I try to find my notes on the 44-46 transfer case needing to see neutral gear to shift in 4low.

    I don’t remember what the workaround is or if there is one.


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  13. Top Of Page | #7

    Re: ZF6 Swap - Possible With BW44-46?

    Looking to hold 600HP.

    Maybe I'm not familiar with how this 4WD system works, but I thought the system is timed such that the axle lock happens first, and then the transfer case locks up the clutch to enable 4WD.

    Not sure if this is true or how it differs from, say, a Ford NV273.


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  15. Top Of Page | #8
    Chrisn162001's Avatar

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    Re: ZF6 Swap - Possible With BW44-46?

    Quote Originally Posted by oMegaOrange View Post
    Looking to hold 600HP.

    Maybe I'm not familiar with how this 4WD system works, but I thought the system is timed such that the axle lock happens first, and then the transfer case locks up the clutch to enable 4WD.

    Not sure if this is true or how it differs from, say, a Ford NV273.
    I can tell you the 44-47 manual case has no synchro unit in it and is installed in the same years as the 44-46.

    600hp is nothing.

    I’d stay 68RFE or G56 if you are intent on the manual swap.


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  17. Top Of Page | #9
    Chrisn162001's Avatar

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    Re: ZF6 Swap - Possible With BW44-46?

    No, the 44-46 is still chain and gear; it has a synchro clutch unit, so it transitions better when shifting into 4wd at driving speeds, hence shifting the fly transfer case.

    It is not clutch applied 4wd.


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  19. Top Of Page | #10

    Re: ZF6 Swap - Possible With BW44-46?

    Well, again, the reason I'm looking into this is that:

    a) I hate the 68RFE so much

    b) I WILL NOT spend $10k on making it built right and

    c) I'd much rather shift gears manually because I don't trust any tune will make it shift the way I want it.


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