In the following, I will show you how to tear down and rebuild your ZF5 transmission with new syncronizer rings,
tapered roller bearings, caged gear bearings, and oil seals.
First, drain the transmission. Then, remove the shift tower housing from the transmission case. Then, punch a hole
in and pry out the three cup plugs that hold the shift rail detent springs in the case. Remove the springs and you can
leave the detents in the bores.
Next, stand the transmission up on its tail end and drive the two dowel pins between the rear housing and main case
towards the rear of the transmission.
Then, remove the reverse gear idler shaft bolts from the case.
Then, remove all the bolts holding the rear housing to the front case. Carefully separate and slide the main case up
and off of the rear housing. Be careful not to get the main case stuck on the shift rails.
Remove the main shift rail.
Pull the reverse gear idler shaft out of the reverse idler gear.
Take out the reverse idler gear, making sure to catch the two caged bearings.
Remove the three socket head bolts holding the shift rail plate to the rear housing.
Strap the shift rails, countershaft, and main shaft together with some ratchet straps in preparation for removal from
rear case half.
Lift out the above strapped bundle.
Lay your parts out to work.
Pull the input shaft off of the main shaft and slide the syncronizer collar off the 3-4 syncronizer body. Catch the
sliding detents and springs.
Inspect the 4th gear syncronizer ring and input shaft/4th gear syncronizer cone for abnormal wear.
tapered roller bearings, caged gear bearings, and oil seals.
First, drain the transmission. Then, remove the shift tower housing from the transmission case. Then, punch a hole
in and pry out the three cup plugs that hold the shift rail detent springs in the case. Remove the springs and you can
leave the detents in the bores.
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Next, stand the transmission up on its tail end and drive the two dowel pins between the rear housing and main case
towards the rear of the transmission.
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Then, remove the reverse gear idler shaft bolts from the case.
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Then, remove all the bolts holding the rear housing to the front case. Carefully separate and slide the main case up
and off of the rear housing. Be careful not to get the main case stuck on the shift rails.
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Remove the main shift rail.
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Pull the reverse gear idler shaft out of the reverse idler gear.
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Take out the reverse idler gear, making sure to catch the two caged bearings.
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Remove the three socket head bolts holding the shift rail plate to the rear housing.
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Strap the shift rails, countershaft, and main shaft together with some ratchet straps in preparation for removal from
rear case half.
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Lift out the above strapped bundle.
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Lay your parts out to work.
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Pull the input shaft off of the main shaft and slide the syncronizer collar off the 3-4 syncronizer body. Catch the
sliding detents and springs.
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Inspect the 4th gear syncronizer ring and input shaft/4th gear syncronizer cone for abnormal wear.
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