[dave295]

towy
I'm also chasing a zf s5 42 replacement. An option I've chased is a reco box imported from the US. They are about $1500-$2000. Most suppliers want a case as an exchange and will charge about $200-$500 extra if you do not return one. They call it a core deposit.
The code for the box reads as
zf- type
s5- 5 speed sychromesh
42- 420 foot pound of torque.
A heavy duty version of the box is the zf s5 47.
I need a replacement for a 1990ish model f150.
The auto option then, for both 2 and 4wd was a c6.
A 2wd c6 with a new prop shaft might be an option.
An older 4 speed new process box out of a 1980's f truck could be an option.
My 1990 f250 2wd has a c6 with a sterling/stirling diff. This has 8 wheel studs instead of the 5 and with 8 dual rear wheels can be fitted making a good tow vehicle.
My 1980ish f100 has a new process box with a 9" diff behind a 6 pot (same as xd or e).
Lots for you to think about.

Cheers

Dave