Zf5 transmission removal

Rondo

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I have to replace my clutch. I have removed the transfer case, the cross members and 2 of the bell housing bolts. I understand there are 6 bolts. Do the bottom two go in from the engine side? I also found one post that said the turbo has to come off. How difficult is that. Guess it is a good time to replace glow plugs. I have 2 or 3 of the gromets where the turbo connects to the intake manifold I guess. The ones that will dump the oil if they leak. Any tips on how to remove the turbo or replace it? How about the exhaust pipes? Do the have to come off? I am disabled due to cancer and multiple back surgeries so I am going slow. It will take be maybe the rest of the week to finish this. Thanks for your help.
 

Nero

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Might be better to pay someone to do it with what you've got going on....

But to answer your question, it depends on which turbo you have. You may need to take off just the down pipe, you may need to take more off.
One the turbo stuff is off, there's a total of 6 bolts to get the trans off. Starter bolts into the adapter plate, you could leave it if you wanted.
 

Rondo

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I am able to do the work, just takes some time. I have plenty of time. So the down pipe goes from turbo to exhaust? And the crossover pipe goes under the engine to the other? I think I got that right.
 

Nero

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Yep you've got it. You shouldn't have to take the crossover off, but down pipe is a must. Most of the time it completely covers one of the trans mount bolts.
 

ROCK HARVEY

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I had to unhook my exhaust pipes to get them out of the way, but my truck has an aftermarket dual exhaust so you might not have the same issue. To reach the top two transmission mounting bolts, you can remove the trans support crossmember and let the transmission/engine tilt back a little bit. I used a 24” extension and a wobble joint to get to the top two bolts. All 6 bolts go in from the transmission side.

When you go to put it back in, get some extra long bolts or threaded rod to act as guides to get the transmission lined up properly with the engine. I fought mine for an hour before I went to the store and got some guide bolts. No problem after that.
 

Rondo

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I removed the down pipe. Removed the rest of the bolts and the trans came out like it was on greased rails. Here is a pic of the clutch. We came back from northern Idaho towing my Jeep. It never should have made it.
 

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IDIBRONCO

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How in the world did that thing even work? Do you have to replace the flywheel too? Since I'm going to Taylor Park over the weekend, I was going to offer to stop by and take a look, but you got it without me.:cheers:
 

Rondo

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since I had no idea what was in it, I purchase a kit that has everything. Flywheel, clutch, pressure plat and all bearings. I also purchased a new clutch fork. Start fresh. The trans has been replaced at sometime as there is yellow marker on the drain and fill plugs. It is very tight and shifts smoothly.
 

Nero

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I removed the down pipe. Removed the rest of the bolts and the trans came out like it was on greased rails. Here is a pic of the clutch. We came back from northern Idaho towing my Jeep. It never should have made it.
Clutch material is for those who don't know how to drive a truck :peelout

Mighty impressive you made it home, cause you have NO clutch material!
 

Rondo

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I agree. We could have been stranded in the middle of nowhere very easily.
 

Nero

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Now that's impressive, good job!
 

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