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.
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.
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 :)"
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 01:51 AM.
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!
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.
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. ;)