ATS 093 Turbo and Water to Air IC

[91f2504x4]

Bearing number was 57508 I bought mine from National Drivetrain Inc.

The arrows point to were the gears were worn on mine,if yours are worn here as well you won't see the wear until you get the gears off the shaft.

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[91f2504x4]

Oh yeah when you pull it apart also be very careful and have a clean area becuase there will more than likely be a few springs and bb's fly out from the synchro assemblies. They only go back together a certain way, so make sure you look at how they come apart. There are 3 spot on the inside of the slider gears that line up with 3 of the openings in the synchro assembly and this is where 3 tabs with bb's and springs go.

 

[bajabomber87]

What the fawk, I hope this sounds a lot more confusing on paper than in person, Ive gone thru valve bodies and modified them but this is scaring me

 

[91f2504x4]

It really wasn't too bad, maybe it just sounds that way. The worst part is getting the bearing off the main shaft. The little springs and bb's are a little tricky to get back in place and keep them there but, you just have to be a little careful when putting it back together. Oh and you can't use permatex to seal the two halves together, or at least that is what I was told a long time ago. You have to use something that dries hard, permatex can get in the little passages and block oil. I will have to go out in the garage and see what the sealant I use is called, tomorrow though, it is too late tonight.


No one told me all the tips about the crap flying apart when you take it apart so I wanted to pass that along to you so that you would be prepared and hopefully not lose anything.

 

[bajabomber87]

Another good reason why these "smaller" forums are great to find info like this.

 

[bajabomber87]

The instructions above worked great until I got to removing the three allen head bolts holding the shift rails in place. I got one out no problem but stripped the last two

I cant get them out even with an easy out

Gona try the easy out on an impact drill tomorrow if I can get a hold of one.

Here's some step by step'ish pics of the tear down and to where Im at now

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Where in the hell do these balls and plates go? they fell to the bottom of the case before I knew it.

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Shift rail out

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Tried everything with this one

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[Agnem]

This is a great topic, and great info! I've copied the original thread into a new one called ZF5 Rebuild, and am cleaning that one up to take all the intercooler talk out of it. Please continue this discussion in THAT Thread. Only post here if you wish to discuss the intercooler, as both may be headed to the tech articles at some point.

 

[bajabomber87]

Ok update, I finally got the last little things finished up to take it for a test drive.

Got a second fan for the intercooler radiator

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Finished the intercooler piping and elbows

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Threw a 6'' tip on it

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Added an F 350 main leaf that was rearched to my original pack, removed the 1/2'' plate that is underneath the spring pack and replaced it with a 1'' plate.

Came out to 4'' of lift and I put 37'' Cooper Stt's on it.

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[dyoung14]

Ok update, I finally got the last little things finished up to take it for a test drive.

Got a second fan for the intercooler radiator

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Finished the intercooler piping and elbows

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Threw a 6'' tip on it

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Added an F 350 main leaf that was rearched to my original pack, removed the 1/2'' plate that is underneath the spring pack and replaced it with a 1'' plate.

Came out to 4'' of lift and I put 37'' Cooper Stt's on it.

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very nice hows that air-water intercooler doing?

 

[bajabomber87]

No idea, it doesnt work. My bosch pump took a crap right out of the box and requires hitting it with a screwdriver to spin.

Only problems I'm having after driving it all weekend is the oil pressure sensor is taking a crap because it says its always low or moves into the red whenever I get on it.

 

[91f2504x4]

No idea, it doesnt work. My bosch pump took a crap right out of the box and requires hitting it with a screwdriver to spin.

Only problems I'm having after driving it all weekend is the oil pressure sensor is taking a crap because it says its always low or moves into the red whenever I get on it.

Make sure that it is just not the connection on top of the sender, mine was doing the same thing the other day and I had to take a pair of pliars and mash the terminal down a little bit so that it would get good contact again.

That really sucks about the water pump already crapping out, you would think that a Bosch would be better than that.

 

[bajabomber87]

Yeah I'm thinking its just an electrical issue or the sender itself is bad. I do have a leaky gasket on the oil feed on the top of the turbo that I'm fixing now but it isnt anything bad enough to cause zero pressure on the gauge.

The bosch pump must be a dud, Ive never had any problems with Bosch before. I got it thru silicone intakes but they said all they can do is send it to Bosch then they'll determine if I get a new one or not. That could take months, so I'm going to have to buy one from Silicone Intakes again, have them send the crap one back to Bosch, let them do their deal, then hopefully I'll get a refund.
Kind of some ****** customer service, I'd think they'd swap my pump out and let them deal with the money end instead of me.

 

[bajabomber87]

Well its been fun guys (sarcasm) but I'm done with this engine, not worth the money or hassle.

I'm picking up a 3.9 Cummins 4bt (125hp, 375ftlbs stock) to swap into my truck. I'm going to turn it up slightly while running my water to air intercooler and push out around 4-450ft lbs.

So if any of you guys want the turbo set up or the brand new SMF and Luk clutch hit me up for parts...actually anything that is IH including the 7.3.

Tyler

 

[crashnzuk]

That's a bummer to do so much work and then ditch it. Do you have any experience with the 4Bs? It just doesn't seem like that's gonna be enough engine if you plan to tow your trail rig and such. My 6B is turned up a bit and runs pretty good, but I couldn't imagine my camper and trail rig latched on and hitting the Sierras, and your truck is easily 1k lbs heavier than mine empty.
Travis..

 

[6 Nebraska IDIs]

Wait, what happened? Why are you giving up on it?
Depending on what you want for the flywheel/clutch kit my brother may be interested. He's already got a line on a Valeo DMF flywheel/clutch kit though so let us know quick.
Sean