ZF5 Rebuild

[bajabomber87]

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Pull gear back

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Be careful, there is a two piece roller style bearing in there

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Remove gear

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Picture explains trying to install the springs and balls until I busted out the laptop and read the instructions I was given before.

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And the 300 degree for 15 mins was perfect. Bearing went right onto the shaft.

 

[91f2504x4]

Great to see that you got it all back together. Have you got everything back in the trans yet?

 

[bajabomber87]

Not yet, but planning on buttoning up the tranny tomorrow. Then if I have time, swap out the fly wheel and install the clutch and pressure plate.

I cant wait to drive it for the first time with a working clutch!


Forgot to add, the bearing had to get cut off because the machine shop couldnt get it to budge off. So that was 30 bucks and the new Timken bearing and race was 57 bucks.

 

[Agnem]

Hey! Are you pointing with that middle finger, or giving us the bird!??

 

[typ4]

Yeah you have to tighten it down within a couple minutes of applying it, it cures because a chemical reaction that occurs when you tighten it down, or something like that.

It cures in the absence of oxygen , that is why it stays sticky outside the case split. Good stuff, expensive too.

 

[sle2115]

Hey! Are you pointing with that middle finger, or giving us the bird!??

Was wondering if we needed to mod that out!

 

[bajabomber87]

Springs and balls put back on the front synchro

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Shift rails and forks back on

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And old coil spacer from my dodge to use as a stand

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Rear housing mounted

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Reverse gear in

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Bolt holding the shaft in

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Shift rail ball cup thing in

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Input shaft in

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Everything

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Plugs and detent springs removed, sorry for the blurry pic.

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[bajabomber87]

Lift the detents up so the rails can slide in when installing the front case

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Finally together

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Shifter top back on

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T-case awaiting install tomorrow

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[91f2504x4]

Looking good, you'll be shifting gears again before you know it.

 

[bajabomber87]

Looking good, you'll be shifting gears again before you know it.

I could shift them before, they'd just grind or not even propel the truck forward

 

[bajabomber87]

Ok t-case back on, put 5 quarts in the tranny and 3 in the t-case to re "break it in" for a few miles.

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SMF on. You WILL need new shorter bolts as none were provided in this kit surprisingly since the 11" Luk kit had them

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Clutch and pressure plate on

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1 hour worth of fanagling with it and it was on!

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Now today I need to reinstall the crossmembers, rear drive shaft, hook up the t-case linkage, bolt on the 5 speed shifter, remount the slave, fill the rear end with oil and its ready for a short test drive.

 

[Agnem]

Looks good. I see you do not support the rear of your engine? I always do just for safety sake.

 

[bajabomber87]

At first I was and had a jack stand under it but the engine didn't tilt back far enough to concern me so I pulled it out.

 

[res0wc18]

so all told what did you spend on the smf conversion? Part numbers?

 

[bajabomber87]

so all told what did you spend on the smf conversion? Part numbers?

I'll update this post tomorrow when I have time to go thru everything.


Anyways the clutch works great.
























But the shifter is difficult to move and I can only get it in 1st and 2nd. At first I could only get it in third, then I rolled down the driveway and was able to hit first and reverse. Then took off in first and hit 2nd. Tried 3rd but no go.
Did I set the detent springs too deep?