Ok danggit. ;)
This old thread pops up every time when searching for information about
rebuilding a ZF yourself and all it is, is a bunch of nay sayin' crap. :/
So I registered today when I got the ZF, I overhauled myself, installed.
I am the dumbest guy on this website forum and I managed to take a '90
ZF S5-42 out of an F250, apart and installed new synchro rings. No big
You can too if you want to or need to bad enough, that's all it took for
me. I called around and learned there was one guy in Tucson every
body was referring to as "the ZF guy in Tucson :)". Asked 'im about all
the special tools needed and he said he didn't use 'em "who can afford
all that stuff?"
To take it apart... "just slam it down on concrete :)"
I don't have any concrete but I do have a big hunk of iron I bought from
the scrap yard...
I made my own holder out of a VW wheel...
No women around here to tell me I can't rebuild my ZF transmission in
the living room neither...
You can't be an "Ace Hammer Mechanic" if you don't have an 8 pound
Oops. Slamming it apart will mess up one of the special snap rings... LOL :)
So, buy a 2+1/4" snap ring, ahead of time, and modify it to fit by grinding
the ears down...
I heated 4th gear's inner race with a couple propane torches because I
didn't want to get it part-way and find out it was too-much to hammer
down. :/ It clinked when I dropped it on. :)
Not that big of a deal, ok? :)
Alvin in AZ
ps- I used a '91 Ford Light Truck Shop Manual.
pps- The 4x10 block of wood has a 15/16" hole drilled into it.