Finally gonna rebuild my ZF-5!

[The_Josh_Bear]

She's never had clean synchros since I got her about 18 years ago...finally all done and time to refresh.

I've pulled the transmission/t-case a couple times before, but:
1. What's your preferred way to pull the trans? As a set or t-case then trans? I have a transmission attachment for my 100lb floor jack FWIW. Last time I did them together and didn't get the center of mass even a little bit correct, it wasn't fun.

2. I've driven the truck twice this week and each time the transmission has troubles getting back into reverse or 1st after coming out of gear, especially when warm. What gives? My clutch master is totally full, no leaks and I have the heim joint mod for the pedal. The pedal isn't appreciably lower that it used to be... can this be from the actual fork bending, maybe? Or something hydraulic? I can't think of it being an internal problem unless it's low on fluid, but it's not leaking either. Even if it was low on fluid 1st and Reverse aren't synchronized.

3. Anybody have a preference for the output seal on the t-case? Mines not great and It's a good time to get after that. I don't know what's quality these days or isn't. Links appreciated!

Thanks in advance!

 

[Nero]

My favorite way to pull the transmission is to pull the engine with it attached, only second by pulling the cab and using a crane to pull it.

On another note, have you considered trying to run some sort of mtf synchromesh? Ive revived a few v dub transmissions with it before. Might be worth a shot to save money and time for a while.

Also, separate the t case and transmission to drop em

 

[Jesus Freak]

I'm curious about these things too, but I can answer #1....

The best way to pull it is to have a really good friend do it for you while you clean and fry fish.

 

[IDIBRONCO]

Last time I did them together and didn't get the center of mass even a little bit correct, it wasn't fun.

Also, separate the t case and transmission to drop em

I think these quotes speak for themselves. Our transfer cases aren't too difficult to bench press up and down. It's not like they're a NP205 or something like that.

 

[ROCK HARVEY]

1: I removed the trans and t-case together but installed them separately. Not too hard either way.

2: Are you at a dead stop when this happens? Are the bushings in your pedal assembly worn out?

3: You might think about rebuilding the 1356 while you have it out to do the trans. They’re simple and the bearing/seal kits are less than $100. I rebuilt mine in an afternoon. Look up “1356 pump mod” to save your TC from potential self-destruction.

 

[The_Josh_Bear]

My favorite way to pull the transmission is to pull the engine with it attached, only second by pulling the cab and using a crane to pull it.

On another note, have you considered trying to run some sort of mtf synchromesh? Ive revived a few v dub transmissions with it before. Might be worth a shot to save money and time for a while.

Also, separate the t case and transmission to drop em

Well aren't you fancy! As for the MTL/MTF that's the only reason my ZF has lasted so long... Redline MTL all the way, baby!

I'm curious about these things too, but I can answer #1....

The best way to pull it is to have a really good friend do it for you while you clean and fry fish.

Awwww man, why do you gotta go an rub it in? I'm the really good friend under the truck while my other friends hand me tools... They don't cook nothin'!!
True story actually... I know more about vehicles just from working on them and enjoying learning about them than anyone I know(that's not on these forums). I don't really know how that happened, I have no training or certifications. I just love mechanical stuff and fixing things!

I think these quotes speak for themselves. Our transfer cases aren't too difficult to bench press up and down. It's not like they're a NP205 or something like that.

Roger, I'll separate them. I think I've done it both ways...but it's been so long that I can't remember ever doing the t-case first.

1: I removed the trans and t-case together but installed them separately. Not too hard either way.

2: Are you at a dead stop when this happens? Are the bushings in your pedal assembly worn out?

3: You might think about rebuilding the 1356 while you have it out to do the trans. They’re simple and the bearing/seal kits are less than $100. I rebuilt mine in an afternoon. Look up “1356 pump mod” to save your TC from potential self-destruction.

1: Sounds good, I think I'll separate them this time around.
2: Yep! I've been driving manuals for about 21 years, I prefer them over slush-boxes. I definitely know when something is fishy! But good call on the bushings, last time I was in there I lubed them up and the play wasn't terrible, but wasn't good, either.
I guess the strange thing is that now that I think of it, it's an engagement problem, not a clutch-throw problem. I say that because when I do get her in gear, it's not engaging right off the floor or anything. The clutch doesn't start to grab until it's about 1/3 off the floor as always.
3:That's probably the best idea, I've been having trouble shifting from 4H into neutral anyway. So a good time to go through it...

Thanks everyone!

 

[KansasIDI]

The clutch doesn't start to grab until it's about 1/3 off the floor as always

That in itself isn’t a problem, unless it makes it harder to put the transmission in gear. At least I think.

I’ve never had a vehicle that engages the clutch right off the floor, sounds potentially hard on the clutch if you don’t quite get it down all the way.

A couple of my friends trucks, a 91 F250 and a 95 F350, engage just above the floor. Guess what. Their firewalls are cracked out around the clutch master cylinder. I haven’t been around any other 80-97 Fords that engage on the floor, for what that’s worth.

 

[The_Josh_Bear]

That in itself isn’t a problem, unless it makes it harder to put the transmission in gear. At least I think.

I’ve never had a vehicle that engages the clutch right off the floor, sounds potentially hard on the clutch if you don’t quite get it down all the way.

A couple of my friends trucks, a 91 F250 and a 95 F350, engage just above the floor. Guess what. Their firewalls are cracked out around the clutch master cylinder. I haven’t been around any other 80-97 Fords that engage on the floor, for what that’s worth.

Yep that's what I was trying to say there-- the *clutch* engages just fine and I'm happy with it, but something funky is going on for sure. I had the cracked firewall issue on my 88 300-6 years ago, my buddy and his father in law eventually got the reinforcement plate in there.
My firewall isn't perfect but has minimal flex for the design and era. Thankfully getting rid of the DMF and going to a LuK has helped that issue, too! I'd like to add a nice rebuilt pedal bracket someday with fancy new bushings, or actual bearings; I've heard of them but don't know the quality.
Just looked at eBay and only a couple used units...nothing rebuilt. I bet we could find some sintered bronze bushings and bore out the bracket a bit or something...gah the little stuff is as annoying as the big stuff.

 

[The_Josh_Bear]

I got to turn a few wrenches today, of course I completely forgot how much auxiliary crap has to come off to drop said transmission... but I'll get over it. Thankfully I didn't go all gorilla style on the fasteners like I used to, most came loose without too much fuss.

Just need to finish pulling the exhaust then it's time for t-case and trans. Whoo!
BTW I'm pretty stoked how well my 3" downpipe has done. It was the first thing I've ever pie welded, and I only have as stick welder, so that wasn't easy! It's still super solid and rusting up nicely. needs a proper paint job! I used a ball type fitting to attach the main pipe to the downpipe, turns out they don't need bolts clamping them together after a while.

 

[Old Goat]

Yep that's what I was trying to say there-- the *clutch* engages just fine and I'm happy with it, but something funky is going on for sure. I had the cracked firewall issue on my 88 300-6 years ago, my buddy and his father in law eventually got the reinforcement plate in there.
My firewall isn't perfect but has minimal flex for the design and era. Thankfully getting rid of the DMF and going to a LuK has helped that issue, too! I'd like to add a nice rebuilt pedal bracket someday with fancy new bushings, or actual bearings; I've heard of them but don't know the quality.
Just looked at eBay and only a couple used units...nothing rebuilt. I bet we could find some sintered bronze bushings and bore out the bracket a bit or something...gah the little stuff is as annoying as the big stuff.

I pulled a Peddle Bracket assy. out of a Bull nose for my 86
several years ago. Bought the new Bushings from the local Ford
Dealer. Wern`t all that pricy as I remember.
Took it apart, wire wheeled all the c rap off it, made it pretty and
shot some paint on it.
It`s easy to disassemble it and R&R the Bushings. If you haven`t
done the Heim Joint mod, easy time when the shaft it out.
Way easier than doing it under the Dash.

The old Bushings were not wore through, and the one out of my 86 didn`t look too bad, one of these day I`ll rip into it and get them replaced.

Did a Google search of Bushings, lots of them out there.
Will take 4 of them.

ford clutch/brake pedal bushings - Google Search

Here they are with free shipping

80-91 Clutch and Brake Pedal Bushings Bronco F150 F250 F350 | eBay

1980 to 1986 Bronco, F150, F250, F350. 1987 to 1991 Bronco, F150, F250, F350. Two bushings install between brake pedal pivot tube and clutch pedal pivot shaft. Two bushings install between clutch pedal pivot shaft and aluminum bracket.

www.ebay.com

Goat

 

[The_Josh_Bear]

Thank you! I can't remember if mine were ovalled or not... that was the big concern. I had it apart and must have put new bushings in and greased it up. Turns out my favorite wheel bearing grease is waaaaay too thick for that application. Doh. Took a few months to lighten up in the cold.

 

[The_Josh_Bear]

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Good Lord that trans is SO AWKWARD with my trans jack...

What do you people without vehicle lifts do? I had to roll it off the jack onto my creeper, and even then it wouldn't clear the frame/bed so I had to roll it onto the cardboard on the ground.
Last time I had an engine hoist through the shifter hole. WAY easier!

To install I think I'll have to slide it under and tip it up onto the bell housing. Then tip it back over onto the jack. I can't see another practical way to get it up onto the jack solo.

Anyway I was pretty annoyed by the time I got her out. It was raining, and my two youngest kiddos(20 months and 4 years) were inside the cab slamming the seats and stomping feet and making each other angry. By the time the trans was down, my youngest was just screaming, he's teething and hungry and tired... but that's how it goes sometimes. It's hard to pull a trans while watching 4 kiddos solo! I'm actually surprised I got it out yesterday with all the interruptions and parenting and such. Maybe when I install it, I'll make sure my wife is home...but no promises.

I've had the ZF rebuild kit calling my name for a year or so, but have the 1356 kit on the way now. @ROCK HARVEY thank you for the tip!

And it was time for a new welding helmet, mine was way too dark and would not adjust to a lighter shade. So my 4 year old had to try it on.

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[Nero]

Every time I R&R one of these badboys I always just strong arm it up.
Probably why I'm in my mid 30s with shoulder issues now, cause I work too hard.

Glad you got er out!

 

[The_Josh_Bear]

You savage!

I could never do that with arms only, but the old straddle plus knees and both arms technique has been used in the past. Works fine as long as you find the sweet spot before dropping that POS on your ribcage. But I'm assuming it'll be wet out here when I reinstall, so I'm trying to keep my back off the ground.

 

[IDIBRONCO]

What do you people without vehicle lifts do?

I jack the truck up enough so that the transmission will clear the frame.
On another subject, how's the quality of the Yeswelder stuff? I've seen their ads, but I haven't looked into buying anything yet. I've been skeptical.