Zf5 removal issues

Austin86250 · Aug 7, 2022

Trying to remove a zf5 out of what I think is a 92 or 93 7.3 factory turbo
Everything is out cross member driveshaft t case clutch linkage and shifters
But I removed the bell housing bolts to realize the passenger side top bell housing bolt is missing not sure if this is effecting my situation or not
Anyways I’m trying seperate The trans from engine it won’t budge at all just 1/4” the engine is supported so I believe the angle is correct and clearing the driver side dowel pin and the passenger side is missing it
Any idea was at that thing til 2 am in frustration my c6 just flew out at that stage

Jesus Freak · Aug 7, 2022

Should just slide out. Maybe the broken bolt has a nasty burr or something. Is the shifter stuff up top free?

Nero · Aug 7, 2022

Two bolts at the top, two on the sides, then the starter. Sure they're all out? Should just fall out. Might get hooked a little on the body pinch weld is all....

hacked89 · Aug 7, 2022

You gotta be rougher. You’re not gonna hurt it. Wait till you put the zf5 back in that thing has to be at the exact right angle to slide together.

ROCK HARVEY · Aug 7, 2022

I agree that the “missing” bolt could be broken and partially holding the trans in place. Like Nero said there should be 6 bolts total, the one by the clutch slave cylinder is kind of hidden.

Probably though, it’s just corrosion on the dowel pin. Try raising and lowering trans a couple inches and to try separating them from different angles. Like has been said, putting it back was the hard part for me. Get some long bolts to act as guides when you go to re-install it, makes life waaaay easier.

Jesus Freak · Aug 7, 2022

hacked89 said:
You gotta be rougher. You’re not gonna hurt it. Wait till you put the zf5 back in that thing has to be at the exact right angle to slide together.

I'm skeptical of your advice on this, I mean dude...... your front clip didn't even line up when you were putting your truck back together!!! I'm just kidding, but I had to mention it.

Austin86250 · Aug 7, 2022

ROCK HARVEY said:
I agree that the “missing” bolt could be broken and partially holding the trans in place. Like Nero said there should be 6 bolts total, the one by the clutch slave cylinder is kind of hidden.

Probably though, it’s just corrosion on the dowel pin. Try raising and lowering trans a couple inches and to try separating them from different angles. Like has been said, putting it back was the hard part for me. Get some long bolts to act as guides when you go to re-install it, makes life waaaay easier.

Yea I know how this should work I’ve already dropped an idi trans I’ve just never imagined it to get so caught up on what I can’t see

hacked89 · Aug 7, 2022

Jesus Freak said:
I'm skeptical of your advice on this, I mean dude...... your front clip didn't even line up when you were putting your truck back together!!! I'm just kidding, but I had to mention it.

Haha. This truck is welded together and parts from 8 different trucks over multiple generations, when it's back on the road shortly I'll collect my award. All trucks that gave there parts were already junked. The trucks original cab mounts and floor were rusted straight through. The body was sitting on the frame instead of the mounts. I figure where I welded in the new cab mounts it gained an inch and I made a hockey puck lift for the front core support. Everything is relatively lined up now, it's not going to SEMA.

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Original "floor and cab mount"
The original cab mount was disintegrated

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hacked89 · Aug 7, 2022

Austin86250 said:
Yea I know how this should work I’ve already dropped an idi trans I’ve just never imagined it to get so caught up on what I can’t see

I've also seen where people had light black RTV around the bell housing when there doesn't need to be and that can make it much more difficult to seperate.

Jesus Freak · Aug 7, 2022

hacked89 said:
Haha. This truck is welded together and parts from 8 different trucks over multiple generations, when it's back on the road shortly I'll collect my award. All trucks that gave there parts were already junked. The trucks original cab mounts and floor were rusted straight through. The body was sitting on the frame instead of the mounts. I figure where I welded in the new cab mounts it gained an inch and I made a hockey puck lift for the front core support. Everything is relatively lined up now, it's not going to SEMA.

You must be registered for see images attach

You must be registered for see images attach

Original "floor and cab mount"
The original cab mount was disintegrated

You must be registered for see images attach

Now that's "getting er dun", now run over to Idaho and help pry that tranny out. When I grow up I hope my 86 is as hacked as your 89.

Nero · Aug 7, 2022

People usually do that due to dissimilar metals causing that white powdery metal glue that happens if they vibrate too much together. Hope they didn't do that in this case.

Jesus Freak · Aug 7, 2022

hacked89 said:
I've also seen where people had light black RTV around the bell housing when there doesn't need to be and that can make it much more difficult to seperate.

Lol, I guess that's how you stop a rear main seal from leaking!!!

Jesus Freak · Aug 7, 2022

Nero said:
People usually do that due to dissimilar metals causing that white powdery metal glue that happens if they vibrate too much together. Hope they didn't do that in this case.

He says it's moved about a 1/4in, it's stuck on something. If only y'all weren't so far away the hacked89 and me could come and tug and snatch at different angles.

IDIBRONCO · Aug 7, 2022

Did you remove the turbo first? The transmission won't come out with it still mounted to the engine.

Jesus Freak · Aug 7, 2022

IDIBRONCO said:
Did you remove the turbo first? The transmission won't come out with it still mounted to the engine.

Good call! (Clapping sounds)

Zf5 removal issues

Austin86250

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Nero

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hacked89

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ROCK HARVEY

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Nero

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