Anyone rebuilt a ZF 5 speed manual transmission? - Diesel Forum - TheDieselStop.com
Ford Diesel Forum / Powerstroke Forum
Ford Diesel Forum / Powerstroke Forum
Go Back   Diesel Forum - TheDieselStop.com > Ford Diesels > 7.3L IDI Diesels (Not Power Strokes)

7.3L IDI Diesels (Not Power Strokes) Technical discussion of topics related to vehicles powered by the 7.3 Liter In-Direct Injection Navistar engines.

TheDieselstop.com is the premier Diesel Truck Forum on the internet. Registered Users do not see the above ads.
Reply
 
LinkBack Thread Tools Display Modes
Old 02-26-2008, 10:00 PM   #1 (permalink)
Member
 
Join Date: Feb 2008
Location: Fairbanks, AK
Posts: 86
My Photos: (0)
Feedback Score: 0 reviews
Question Anyone rebuilt a ZF 5 speed manual transmission?

Hey I was wondering if there was anyone out there who has done a rebuild on a ZF 5 speed manual transmission. I know I've got a ZF 5 speed but I'm not sure if it is the ZF S5-42 or the ZF S5-47. Just haven't taken the chance to check the tag on the outside of my transmission. I having been trying to find information on rebuilding this transmission and specifically was wondering if anybody had a rebuild manual for the ZF 5 speed manual transmission. I've been able to find a blow up of the parts for these transmissions but I was hoping to find something a little more in depth referring specifically to the rebuild of the ZF 5 speed. Also I have the "How to rebuild and modify your manual transmission" book which is handy but doesn't help me with specifics of the ZF 5 speed. If anyone can help me out with finding out more information regarding a rebuild manual for the ZF 5 speed manual transmission it would be extremely helpful.

Also some vehicle information: 1990 F250 7.3L IDI 4x4 and I'm fairly certain this is the original transmission.

Thanks
George
__________________
1992 F350 7.3 Liter IDI Four door long bed 4x4 5 Speed Manual ZF. Future: ATS Turbo, John Deere green paint job, gear vendor overdrive kit, Herculiner for the bed, and WVO fuel kit. Also 1990 F250 7.3 Liter IDI two door supercab with 5 Speed Manual ZF planning to sell after I pull my cd player, CB radio, and slider back glass out.
George_7.3IDI is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 02-26-2008, 10:39 PM   #2 (permalink)
Senior Member
 
DaveBey's Avatar
 
Join Date: Oct 2000
Location: Claremore, Oklahoma USA
Posts: 5,972
My Photos: (203)
Feedback Score: 0 reviews
George -- Howdy and welcome to TheDieselStop.com!

You have the ZF S5-42 manual transmission. The ZF S5-47 wasn't introduced until the 1996 model year.

This is for the S5-47 but it may help you with your S5-42: Transmission, Manual, Model S5-47 ZF

Cheers from Tulsa, OK!
Dave
DaveBey is offline   Reply With Quote Quick reply to this message
Old 02-28-2008, 05:04 PM   #3 (permalink)
mm
Senior Member
 
Join Date: May 2001
Location: lower Michigan
Posts: 131
My Photos: (0)
Feedback Score: 0 reviews
I bought a Ford zf -42 manual off ebay, sorry, can't sell. Can put the heavier zf-47 sycros in a zf-42 if you not going to use PTO option.
__________________
1992 F250, 5 speed, extended cab, replaced 7.3 with 6.9 2-5-08
DewEze round bale carrier
mm is offline   Reply With Quote Quick reply to this message
Old 02-28-2008, 10:24 PM   #4 (permalink)
Senior Member
 
Bill1013's Avatar
 
Join Date: Mar 2007
Location: Delphos, Ohio
Posts: 2,713
My Photos: (0)
Feedback Score: 0 reviews
http://www.zf-group.com/pdf/S5-42.pdf

Look at this and see if you really want to tackle a job like that . Looks daunting to me .
__________________
99.5 F350 XLT Lariat 4X4 4R100 4.10 DW CC LB Centurion conversion Garret Turbo, Radio SD &Tape, SP Performance 40-60-80 chip, 100 Gal.Transfer Flow W/Trimax Control Aux. fuel tank. ScanGaugeII, Boost, EGT, Trans. Temp. Oil Temp. Build date 03/99

92 F350 7.3 IDIT E4OD CC LB dually Banks turbo US Gear O/U

Have AutoEnginuity W/Ford enhanced. Lima OH area.

My mind works lightening fast.
One Flash and it's gone forever.
Bill1013 is offline   Reply With Quote Quick reply to this message
Old 02-28-2008, 10:31 PM   #5 (permalink)
Senior Member
 
ron68coug's Avatar
 
Join Date: Feb 2008
Location: WA
Posts: 226
My Photos: (6)
Feedback Score: 0 reviews
I looked into it for my 94, it seems cheper to buy a rebuild. They company I work for has a full shop that does heavy equip. They buy rebuilds. Too much involved.
__________________
02 Ford Excursion 7.3L, 4x4, black/black trim, 4" lift, 35" duelers on (black w/chrome accents), 17's, 170K miles, Monster trans. w/John Woods accumulator, '07 Harley front end, Ranchhand bumper and Superwinch, 25" CREE LED 15,000 lumen lightbar, '08 heated mirrors, 2.5" cowl hood, Riff raff intake mod, 203 degree t-stat, Mishimoto radiator, Superchips programmer, F-350 crewcab nerf bars, Limited 2 tone leather interior, 16.5 roof mount television and Pioneer DVD touch screen head unit with 1200w amp feeding the mids and highs, and 1600w going to the 2 Rockford Fosgate 12" P3's. Viair 480C compressor and Nathan P3 train horns.

Wrecked--gone but not forgotten
01 F-350 CC DRW 4x4, bright red, 7.3
ron68coug is offline   Reply With Quote Quick reply to this message
Old 11-25-2009, 10:35 PM   #6 (permalink)
Junior Member
 
Join Date: Nov 2009
Location: Gadsden Purchase :)
Posts: 15
My Photos: (0)
Feedback Score: 0 reviews
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
deal. :)

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...
http://www.panix.com/~alvinj/file12/zf3.jpg

I made my own holder out of a VW wheel...
http://www.panix.com/~alvinj/file12/zf2.jpg

No women around here to tell me I can't rebuild my ZF transmission in
the living room neither...
http://www.panix.com/~alvinj/file12/zf1.jpg

You can't be an "Ace Hammer Mechanic" if you don't have an 8 pound
single jack...
http://www.panix.com/~alvinj/file12/zf4.jpg

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...
http://www.panix.com/~alvinj/file12/zfSR.jpg

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. :)

Finished...
http://www.panix.com/~alvinj/file12/zfF.jpg

Had then...
http://www.panix.com/~alvinj/file12/hoist3a.jpg

Have today...
http://www.panix.com/~alvinj/file12/hoist7m.jpg

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.

Last edited by Alvin in AZ; 01-03-2010 at 12:45 AM.
Alvin in AZ is offline   Reply With Quote Quick reply to this message
Old 12-29-2009, 06:08 PM   #7 (permalink)
Senior Member
 
Join Date: Sep 2002
Location: Albion, Michigan
Posts: 543
My Photos: (2)
Feedback Score: 0 reviews
Alvin, you're my idol....
__________________
1997 F250 Supercab XLT Powerstroke / E40D / 4x4
2005 Volkswagen Golf GLS TDI
1986 F250/XLT/Lariat/6.9/4sp/Supercab/ATS turbo
1985 Bronco/XLT/is getting the 6.9 Turbo.
86turbodsl is offline   Reply With Quote Quick reply to this message
Old 12-30-2009, 02:46 AM   #8 (permalink)
Junior Member
 
Join Date: Nov 2009
Location: Gadsden Purchase :)
Posts: 15
My Photos: (0)
Feedback Score: 0 reviews
Quote:
Originally Posted by 86turbodsl View Post
Alvin, you're my idol.... :)
Cool, thanks. LOL :)

You need to know that you're idolizing a "stupid ugly old Gringo" tho. :/

----------------------------

Lately it's really sinking in that rebuilding a manual transmission is
pert-near fool proof and easy when compared to an engine or axle.

But getting parts for the ZF is not as straight forward as it could be.

"you can do it, if you want to"
Don't let the Ford service manual spook ya. ;)

BTW, there's a mistake in the manual...
Assembly step #13 has the wrong picture, kinda threw me for about
a half hour. LOL :) Glad I took some pictures first. ;)

Also, there's 3 "sliding sleeves" that are moved by the shifting forks.
Two of mine were marked "Front" one "Rear" and each with an arrow.
That's real cool and all, but one of the one's marked "Front" had the
arrow pointing toward the -rear-. :) Didn't check to be sure if it even
mattered which way it was put in. :/ Meant to.

So look it over real good and be sure of what you've got in yours.

Alvin in AZ

Last edited by Alvin in AZ; 12-30-2009 at 02:51 AM.
Alvin in AZ is offline   Reply With Quote Quick reply to this message
Old 01-01-2010, 01:48 AM   #9 (permalink)
Senior Member
 
Join Date: Jul 2004
Location: SF area
Posts: 238
My Photos: (0)
Feedback Score: 0 reviews
Thumbs up

V cool alvin.. this plays into my fantasy of a diesel zf 5spd w a "460" first gear in it ...... I'm putting a 5spd in my van ... much fun
__________________
'91 E350 7.3 , facet Duralift fuel pump , snglmass flywhl, ZF 5spd trans, 2 piece drive shaft, 3.55 d60 lsd moosiahmobile project.... '81 volksdiesel Frankenbunny ,more Audi than Golf OR Rabbit!
moosiah is offline   Reply With Quote Quick reply to this message
Old 01-01-2010, 10:18 AM   #10 (permalink)
Senior Member
 
NH2112's Avatar
 
Join Date: Oct 2009
Location: Windham, ME
Posts: 2,269
My Photos: (2)
Feedback Score: 1 reviews
Send a message via MSN to NH2112 Send a message via Yahoo to NH2112
A diesel case with 460 1st gear would have one hell of a jump between 1st & 2nd, would swapping all the guts be possible or feasible? You'd get the lower reverse as well.
__________________
Phil

Check my lists of common part numbers in my photos! Updated often!

1991 F350 Lariat XLT, 7.3l, 5-speed, crew cab, SRW, 3.55, 2WD.

1990 Jeep Wrangler Sahara, in the process of a major overhaul/upgrade. OM617 on the horizon! Front & rear Dana 44s from a Wagoneer till I get some 1-ton axles built & narrowed, and eventually a front shackle reversal. Diesel YJ, bay-BEE, and not a cookie-cutter 4BT conversion!
NH2112 is offline   Reply With Quote Quick reply to this message
Old 01-03-2010, 12:39 AM   #11 (permalink)
Junior Member
 
Join Date: Nov 2009
Location: Gadsden Purchase :)
Posts: 15
My Photos: (0)
Feedback Score: 0 reviews
Quote:
Originally Posted by NH2112 View Post
A diesel case with 460 1st gear would have one hell of a jump
between 1st & 2nd, would swapping all the guts be possible or
feasible? You'd get the lower reverse as well.
What are the ratios you are talking about there?

I don't know if this will help or hinder you... :)
http://www.panix.com/~alvinj/file12/600rpm
...the file just started out as notes but kept growing.

Alvin in AZ
Alvin in AZ is offline   Reply With Quote Quick reply to this message
Old 01-03-2010, 12:51 AM   #12 (permalink)
Senior Member
 
Plywood's Avatar
 
Join Date: May 2008
Location: Portland Oregon
Posts: 1,242
My Photos: (13)
Feedback Score: 0 reviews
High Impact - ZF 5spd

This page gives some of the info.

http://www.gearvendors.com/fdrive.html

Some more.
__________________
85 F250 XLT Lariat 4x4 7.3L N/A, C6, 315/75/16 Siped Wild Country Muds, Manual ZD9s, K&N, Soup Bowl Out, Dura-Lift Pump, Dynomax 3" Y-pipe-4" AFE Muffler-5" Turndown.
http://www.youtube.com/user/Theonlyplywood#p/u
Turn it up!

Last edited by Plywood; 01-03-2010 at 12:54 AM.
Plywood is offline   Reply With Quote Quick reply to this message
Old 01-03-2010, 02:15 PM   #13 (permalink)
Junior Member
 
Join Date: Aug 2006
Posts: 12
My Photos: (0)
Feedback Score: 0 reviews
rebuilt my ZF5 myself in 03 when I still had my 89. No big deal, no special tools, just baught a Haynes manuel to have pictures. You can do it! tim
timsmitty is offline   Reply With Quote Quick reply to this message
Old 07-31-2010, 01:22 PM   #14 (permalink)
Junior Member
 
Join Date: Apr 2009
Posts: 3
My Photos: (0)
Feedback Score: 0 reviews
Alvin, Unbelievable! haven't laughed so hard when researching IDI stuff.... Ever! especially like the fair warning on what i might break, just in case, so i can have the parts on hand! Have a great day you just made mine.
RWilles is offline   Reply With Quote Quick reply to this message
Old 08-01-2010, 06:01 PM   #15 (permalink)
Junior Member
 
Join Date: Nov 2009
Location: Gadsden Purchase :)
Posts: 15
My Photos: (0)
Feedback Score: 0 reviews
Quote:
Originally Posted by RWilles View Post
Alvin, Unbelievable! haven't laughed so hard when researching IDI stuff....
Ever! especially like the fair warning on what i might break, just in case,
so i can have the parts on hand! Have a great day you just made mine.
Cool glad to hear it. :)

Here's a "secret" directory I copied the most needed ZF pages of the
'91 Ford Shop Manual into...
Index of /~alvinj/etc
...big files so they'll make clean copies.

I took notes in the book (as I always do) and some of them are kinda
dumb sounding but they weren't meant for the world to read when I
wrote 'em. ;)

Alvin in AZ
Alvin in AZ is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

  Diesel Forum - TheDieselStop.com > Ford Diesels > 7.3L IDI Diesels (Not Power Strokes)

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Diesel Forum - TheDieselStop.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



Wheel & Tire Center

Powered by vBadvanced CMPS v3.2.3

All times are GMT -5. The time now is 10:06 AM.



Powered by vBulletin® Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Search Engine Friendly URLs by vBSEO 3.6.0

vBulletin Optimisation provided by vB Optimise (Pro) - vBulletin Mods & Addons Copyright © 2014 DragonByte Technologies Ltd.