Pulling Hair Out with ZF5 Install - What's the Trick to Installing One?

Jesus Freak

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Oh boy, look at that pto.

By the way, did you know that some transfer cases came with a pto option? I was under my truck the other day and forgot mine had it. Big ol rectangle plate on the side of it.
I didn't know that! But now I know and knowing is half the battle.
 

The_Josh_Bear

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I fought my ZF5 for what seemed like forever and then ended up picking up on the front of the engine to change the angle and then I was able to get it to go. If it isn't going just recheck your angles. Good luck.
Same here. Boy do I love working alone...
 

Kdo58

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I had to hook up my engine hoist, to get a better angle. Was at a transmission shop and they had the rear of the cars jacked way up, guessing using the weight of the transmission to slide in?
 

IDIBRONCO

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I fought my ZF5 for what seemed like forever and then ended up picking up on the front of the engine to change the angle and then I was able to get it to go. If it isn't going just recheck your angles. Good luck.
I like to look up at the bellhousing and adapter plate from underneath while I'm installing a transmission to check the angles. That and checking the gaps on each side can tell you how to move the transmission.
 

bulletpruf

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And, I'm not trying to be a butt, but maybe do the alignment tool again just to make sure that the clutch is centered. And try yelling, nothing vulgar, just kinda like Stallone in a Rambo movie. It might not get the tranny any closer, but you'll feel better.........I promise.......AAAAAHHHHHHHHHHHH!!!!!!!!!

Well, you were definitely on to something here! I looked at the clutch and pilot alignment and saw that the clutch disk wasn't quite centered. Pulled the pressure plate off and reinstalled but this time I eyeballed it to make sure it was straight and didn't use the alignment tool.

From there, I tried to use bolts to pull it in again, but stopped when it started to bind a bit. Then I took the bolts out, but left in the all thread in the lower bolt holes. From there, I wrassled with it for a while, turning the output shaft periodically, and right when I was about to give up and pull the engine, it went in!

Got the bolts torqued to 60 ft/lbs and got the crossmember in, too.

Thanks for all the input!

Scott
 

Rdnck84_03

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Atleast y’all have tranny jacks! Trying to alight the clutch splines while you benching a the trans is not fun
Been there with a 4x4 t18, that was 20 years ago though. I doubt I could even get the damn thing on my chest now, let alone bench press it into place.

James
 

Jesus Freak

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Ouch... Yeah I don't have a trans jack, just a harbor freight low profile floor jack...
Me too, but I made a little platform for transmissions that I can ratchet strap it to and the tranny can't fall off the floor jack.
 

david85

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No trans jack here either. I keep telling myself that it happens so rarely that I don't need one. Floor jack, wood blocking, and the latest stat of the art innovation: straps between the frame rails.
 

bulletpruf

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I've been there with no trans jack before. When I was stationed in Korea, I ended up swapping out the NP246 transfer case in my '99 Yukon in the parking lot of my housing complex in the freezing rain. Not a lot of fun, but better than bench-pressing a ZF5.

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Old Goat

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quite a few years back I was swapping out my auto trans in my 85 Mercedes 300D, for manual 240D 4-spd trans.
I picked up this HF Jack and for the most part was ok. That trans only weighed 53lbs.

Later on, maybe 5 yrs ago, I needed to drop the T-19 out of my 86 F-250. No way was I going to use it.
I needed a larger Jack. Located a HF Trans jack on CL. Guy used it one time, and wanted it gone, gave me a great price. Think I paid $80.
Easy to use and very stable compared to the first one.

Must be a good one, has the Prop-65 endorsement. ;Really


Goat
 

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