zf5 teardown questions

[dagreendeville]

well thanks guys i finally had time to tear mine apart the manual that dan emailed was great i had no problems with the tear down now its time to go buy a new 3rd-4th gear shift fork as mine broke the only other issue i had was popping out of reverse im going to have the syncros and everything looked at when ni pick up my parts and i agree there should def be a rebuild write up..... also so far this has been a very simple teardown

[dancrowley]

Good info, thanks! I have been looking at these ebay kits. There is either this kit or this kit. One is cheaper than the other but its hard to know which might have better quality components. The money's not really the issue. Like I mention in the captions of teardown pictures, this thing needs to outlast the truck once installed. Also going to spring for all new gear roller bearings.



Interesting! I searched the ZF part number for the "shim kit" (you can't just buy one) and I was seeing very high prices. Even so, $100 is still a bit high when you will only be using 2 shims from the kit. Maybe a dedicated trans shop could sell individual.

I'll dig out my receipts for all my ZF parts and list what I bought and what I paid, again I went with all genuine ZF parts. Dan

[dancrowley]

These are the ZF parts that I have bought and how much that I paid for them. Like I said; I wanted all factory parts and I paid top dollar for them.
PART #'s
ZF BB/DSL 4X4 Mainshaft 18.78" 1 EA $ 135.42 ==== ZF-42-2
ZF S542 Snap Ring Kit 1 EA $ 67.48 ==== SRK-1307
ZF S542 Shim Kit 1 EA $ 94.07 ==== 1307SMK
ZF Idler Shaft Bolt-All ZF'S 2 EA $ 3.14 ==== 0636101663
ZF S542/S547 5 Speed Minor Kit 1 EA $ 133.72 ==== 1307Minor
ZF Blocker Kit 1 EA $ 179.24 ==== 1307SK (Syncro's)
ZF Needle Bearing Kit S542/47 1 EA $ 41.71 ==== 1307NK
ZF Syncro-Ball-Key-Spring Kit 1 EA $ 34.95 ==== 1307PPK
ZF Plastic Shifter Guides 2 EA $ 3.96 ==== 1307-306-154
ZF S5-42 Inner Boot 1 EA $ 8.75 ==== 1307-306-236
ZF Detent Pin 1 EA $ 9.99==== 1307-306-170
ZF Detent Spring All ZF'S 1 EA 9.30 ==== 0732041946
ZF Rev Stop Plate Compression Spring 1 EA $ 2.45 ==== 0732041947
ZF S5-42 Stop Plates 1 EA $ 3.84 ==== 1307-306-229
ZF Clutch Pivot Ball 1 EA $ 5.25 ==== 1307-301-011
ZF S5-42 Manual 1 EA $ 10.00
ZF S542 Back Up Switch 1 EA $ 9.95
ZF S542 Bearing Guide Tube 1 EA $ 7.00
S and H $71.50 Total $821.77

[kawamatt]

So you were converting to 4x4?

I assume the "minor" kit came with syncros and tapered bearings? Or are these things in the "blocker" kit?

A complete needle bearing kit, if it includes all the bearings for each gear, for $40 is amazing. I am assuming this was just the shift rail bearings.

Do you have a number on the "inner boot" for $9? The cheapest I can find it for is $45. Inner shift boot

It would be super helpful if you saved the packaging and could post all the part numbers for each part of the order you placed. I am sure the P/N's were on the invoice if you threw the packaging away.

[kawamatt]

So some more info for those looking to rebuild their ZF5's.

After reading dancrowley's list I realized that maybe a person could buy individual parts instead of a whole "kit" as it were. Some googling led me to this guys rebuild thread. He mentions he purchased a "Transtar" rebuild kit. Some more googling led me to this transtar manual transmission catalog. About page 180 starts the ZF parts.

Back to google and searching using the P/N's in the furthest right column and I've stumbled on a bearing shim kit for the input shaft for only $17. Nice! DTS-ZF42-SMK This price seems too good to be true though. Also can't find a shim kit for the countershaft. Transtar lists the P/N for the input shim kit as ZF42-SMK and for the countshaft as ZF42-SMKA.

[Agnem]

The only thing that I can contribute, haveing not done this myself yet, is that consultation with my trusted mentor and Ford technician Bob reveals that it is not uncommon for a ZF case to "stretch" under heavy load. This can make rebuilding more "fun" than you can imagine. Good luck!

[dancrowley]

The Minor kit had the tapered bearings and some gaskets and some seals. The blocker kit was the syncros. The needle bearings came in their own kit. The syncro-ball-key-spring kit, shifter guides, inner boot, detent pin and spring, rev. stop plate compression spring and plates were all in one sealed bag. This is a 4X4 trans. Dan

[riotwarrior]

The Minor kit had the tapered bearings and some gaskets and some seals. The blocker kit was the syncros. The needle bearings came in their own kit. The syncro-ball-key-spring kit, shifter guides, inner boot, detent pin and spring, rev. stop plate compression spring and plates were all in one sealed bag. This is a 4X4 trans. Dan

KIT PART NUMBERS PLEASE?????

[dancrowley]

The part #'s have been added to the list of parts. Dan