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Power Strokes 1994-1997 General Technical discussion of topics related to vehicles powered by the Power Stroke engine in 1994 through 1997 models.

       
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Old 09-03-2008, 10:20 PM   #1 (permalink)
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ZF tranny problem

Was trying to change out the trans fluid in the 5-speed, and couldnt get the filler plug out. Ended up stripping it, and had to tear it up with a chisel to get it free and back it out. Dont know why the heck it was in so dam tight, the drain was so tight had to use an impact to get it out. ANYWAY, where the heck do I get a new filler plug? It is a straight thread with a flange that seals to the tranny. Dorman make replacements or it this a friggin dealer thing? Any help appreciated. I Tig welded a nut to it, and tried to fix the torn up flange so I can at least drive the truck, but its leaking already.

Thanks
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**03 F150 Crew, Harley Edition, blower motor, chipped, exhaust, intake, lowered 3, fast
**01 Fatboy, 95" motor, cam, exhaust, ported/polished, rolls out!
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Old 09-03-2008, 11:13 PM   #2 (permalink)
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Quote:
Originally Posted by mohead1 View Post
Was trying to change out the trans fluid in the 5-speed, and couldnt get the filler plug out. Ended up stripping it, and had to tear it up with a chisel to get it free and back it out. Dont know why the heck it was in so dam tight, the drain was so tight had to use an impact to get it out. ANYWAY, where the heck do I get a new filler plug? It is a straight thread with a flange that seals to the tranny. Dorman make replacements or it this a friggin dealer thing? Any help appreciated. I Tig welded a nut to it, and tried to fix the torn up flange so I can at least drive the truck, but its leaking already.

Thanks
Grease a pipe tap up real goo and tap it out and put a pipe lug in it. The reason they stick so bad is that the dissimilar metals becomes a corrosion point. They can be a real pain to get out as you have seen. Another way is to get the drain out like you did and fill it through the shifter. capacity is 3.8 qts I think. Most people claim better operation with a rounded off 4 qts. You have to fill through the shifter for that.
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Old 09-05-2008, 12:10 AM   #3 (permalink)
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From the stuff I have (not that its that helpful):

ZF# 0501 209 879, Screw Plug M22 x 1.75, Ford# F81Z 7A010 AA

ZF# 0636 304 049, Screw Plug M24 x 1.5, Ford# E7TZ 7A010 C

ZF# 0636 304 150, Screw Plug M24 X 1.5, Can't cross it to a Ford number

Don't know which one it actually is, but you can probably figure it out. Cheers!
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Old 09-05-2008, 07:33 AM   #4 (permalink)
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Probably a dealer bolt. I would guess it will be a 10 dollar bill.

I agree the drain is a pain. I always end up with a 6' cheater so I can be out from under the truck and stand to loosen it.
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Old 09-05-2008, 10:20 AM   #5 (permalink)
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Thumbs up Plug Sizes

Hey Patrick,

Thanks bud, thats exactly what I was looking for. I am not a big metric measurement fan, but can get it close I imagine. So M22 is the millimeter diameter and the 1.5 is length?? Is that right? Looking at plugs on the Dorman web page, I think I remember a similar sized plug on there. May just crap out and go to the "stealer" and order one. But thanks much for the info, that helps.
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**97 F250HD Supercab, PSD, 5-spd., 4.10, long bed, fpr mod.,HPX mod, 203 stat, Diamond Eye 4" exhaust, AFE intake and Scorpion switch chip.
**03 F150 Crew, Harley Edition, blower motor, chipped, exhaust, intake, lowered 3, fast
**01 Fatboy, 95" motor, cam, exhaust, ported/polished, rolls out!
**07 Screaming Eagle Dyna, all the goodies, 110" motor, torque monster, wheels up third gear
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Old 09-05-2008, 08:15 PM   #6 (permalink)
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M22 or M24 is the millimeter diameter and the 1.75 or 1.5 is the thread pitch (millimeters per thread). Cheers!
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1994 F350 CC DRW 2WD PSD (ALF4), ZF 5 Speed, 4.10 LS, SBC Con-O SMFW/Clutch, Baldwin Filter, Tymar HPX Hose, DPPI DP, Bilsteins, $12 AIC, Coolant Filter, Stancor GPR, Explorer Overhead Console, A-Pillar w/ISSPRO Black Ice, EV Boost, and EV Pyro (pre-turbo) , Relocated Block Heater Plug, Modified Pedestal, Gutted EBPV.
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