ZF S5-42 Transmission Full Teardown and Rebuild

Рет қаралды 100,444

5 жыл бұрын

In this video we will be rebuilding the ZF S5-42 transmission from my truck.
Let me start off by stating that I am not an expert, just a guy in his garage with a rebuild manual. The reason for rebuilding is bearing noise, difficult downshifting from 3rd to 2nd, and "slop" when you let up on the gas. These issues have been mostly fixed, but not fully. These ZFs are known to have some bearing noise, even when new or freshly rebuilt, which explains why there is still some noise present.
I was able to tackle most of this job with common tools, but did have to rent many types of bearing pullers from O'Reilly's and AutoZone. The two tools I ended up buying were an 8" jaw puller from Northern Tool, and an OTC 6542 bearing cup puller.
Information:
Here's the rebuild I saw on the forums - www.oilburners.net/threads/zf...
Rebuild manual PDF - www.vaglinks.com/Docs/Catalogu...
Parts suppliers:
Midwest Transmission - Synchro slider, slider detent balls
Nogalitos Gear - Shim kit
Allstate Gear - Shifter rebuild kit, output flange nut
eBay - Rebuild kit
Tools used in this video:
Milwaukee Impact Gun: amzn.to/2ZlFPPE
Milwaukee Drill: amzn.to/2KOTX00
Condiment Bottles: amzn.to/33QCkEk
OTC Bearing Cup Puller: amzn.to/31Ub5ag
8" Gear Puller: amzn.to/2DihOk1
Anaerobic Gasket Maker: amzn.to/320Yan7
Disclaimer: The content provided in this video is for informational use only. Video content is provided at the viewers own risk and the viewer will not hold the parties involved in creating, producing or delivering this information liable for any loss, injury, claim, liability, or damage of any kind resulting in any way from any errors in or omissions from the information. Thanks for understanding.

Пікірлер: 98

@-Oclock Жыл бұрын

"i dont know what im doing and you cant stop me" hilarious, great video too.

@RandBfolife Жыл бұрын

I appreciate your video. It helped me vastly overhauling my S5=47. I recommend swapping the toaster over. Used a cheap air fryer on bake for 12 minutes 330 degrees and I did much less hammering. Bearings, synchro gears, thrust washer and sleeve all went right on, effortless except one synchro gear took 3 or 4 light taps. Saved a ton of time.

@CarlosTorres-sk5gy 4 жыл бұрын

I'm getting ready to do mine, after watching your video I feel I'm ready. Thanks for a great video, loved seeing you work around the minor setbacks. Great video!!

@jegustaeau 4 жыл бұрын

Very helpful video. Thanks for taking the time to record all of this!

@chicoshovelhead 3 жыл бұрын

This is my go-to video for pulling these transmissions apart. I pulled my first one apart that was stuck in second gear. I ended up seperating it up side down (bell housing down) and lost a few small parts in the process (DOH). Went and bought another used trans for $600...and found cracks in the bellhousing when I went to install it. Had a friend come tig the crack...then found another when I almost had it lined up. Today...today I am going to swap cases. Pull the gear set out of the cracked case, and put the gears into the good case. An extreme fuckstory that I am 100% sure is half my fault. So, here I go. I feel confident after watching the first couple of minutes of your video. Thank you for that. Oh, and the dry commentary is cool too. If I can't figure it out this go round I may just take a sledge hammer to the lot.

@TheRedneckStig 3 жыл бұрын

If I can do it on a piece of scrap cardboard and harbor freight tarp in a storage unit in the heat of summer then you can too!

@Satatic Жыл бұрын

This is gonna help me a lot. I've got tired of arguing with local transmission shops about how my trans with 391,000 miles can't possibly have slop while downshifting and engine braking in some gears but not others. Them wanting me to let them spend a month taking it apart and ordering parts. Ill just do it myself. Based on this video I think I have some worn needle bearings under some gears. And the thing about the slider ring wear helps to because I can now pre-order them since I often grind into reverse and grind 1-2. I bet mine are worn down. Maybe I'll only be down a few days. Thanks.

@VGHCX Ай бұрын

Giving socket/wrench sizes used is very helpful on these types of videos.

@norb0254 4 жыл бұрын

Excellent video ,you can still get the ZF 5S42 in Europe on 7.5 tonne trucks ,the only difference is the casing is slightly different ,still a 2 piece and internals are the same except we do not use synchro on reverse at all..I have done literally hundreds of these boxes ..A few tips I can give,When you where removing the bearing sleeve at 3rd and 4th since as you found out it is an interference fit and tight to come off ,once I have the puller applying pressure ,I then use a electric heat gun which expands it and it then pops off...the sleeves can fit either way ,and if you look at the one for 3rd/4thyou may see small arrows with front stamped on the edge ,they are small. I would if I was you get a hotplate ,where you can get the part hot enough to fit easily ,as I bet you had fun putting that sleeve back on lol...Lastly I know you followed the book to the letter and there is nothing wrong with that ,I have found on all the boxes that I have done ,and I have never had an issue ,and there is no tightness ,that you can leave the factory shims in and it is ok..Though I have always used OE parts ,I don't know if you did ..But keep up the good work .Gearboxes are not as scary as people think,,easier than an engine

@fyst4413 2 жыл бұрын

A bit late to the game, but have you ever rebuilt an s5 35?

@norb0254 2 жыл бұрын

@@fyst4413 it is identical to do ..Have done 100s ,though we don't see them anymore where i am ,The 6 speed AS-Lite is the box of choice here nowdays

@fyst4413 2 жыл бұрын

@@norb0254 Thanks! i have the s5 35 transmission in an old skidder that i have. but i cant find mauals online, any help? ;)

@norb0254 2 жыл бұрын

@@fyst4413 The 35 and 42 just relate to the torque 3rd and 4th for example the grooves on the rings may be oriented differently and the sleeve may in tiny writing have front on it ..If doing it for the first time get a rod on a flat base and as you take a part off put it over the rod keeping everything in the correct order and orientation

@andrewwilliford114 6 ай бұрын

Thank you that was helpful!!

@mulletman5750 5 жыл бұрын

You saved my life dude lol I couldnt figure out where this little spring went until you took the shifter plate off and took that little metal piece out. Thank you so much.

@KrazyKuul111 3 жыл бұрын

This is awesome because I am replacing the rear tail housing on mine, and you cover EVERYTHING needed to know to replace one, plus more. Excellent job, really, thank you so much for sharing your journey. I have one small thing to mention though. When you apply the anaerobic gasket maker, i would be careful to not apply too much, and I would then smooth it out with my finger. You see how it squeezed out on the outside, it surely did on the inside too. Awhile back, on another project, I heard about someone having oil pressure issues with their engine. It was because they used too much rtv when replacing the oil pan; it squeezed out on the inside and eventually plugged the oil pickup screen on the oil pump. Fortunately, I cant see it doing any damage in a manual transmission

@gregory9740 5 жыл бұрын

Man im in the process of rebuilding mine, i have to take reverse and fifth back out because the teeth on the slider wasnt lined up with the ball bearings. No biggy tho im going to replace the 5th gear slider now because of what you mentioned here. Im just glad i caught the ball bearing thing when i did 1-4 gears. Good job on this video and thanks for making it.

@Racerboy535 Жыл бұрын

A quick and concise video. You made it look easy and have given me the confidence to take this on for my manual truck swap. I appreciate the time you’ve taken to video and edit this. FYI. If you put the races in the freezer they will slide in without needing to hammer them home. .002 friction fit if they slide in they drive home a lot easier.

@KrazyKuul111 3 жыл бұрын

I just got my ZF5 back together the other day and in my truck. thanks so much again for your video

@garrettwheeler266 4 жыл бұрын

I wish this video was around when I rebuilt the transmission in my 1997 7.3 it would have saved me a lot of time

@Americal1970 8 ай бұрын

I like the way ZFs shift, reminds me when I was in the Army.... When my balls were BIG

@MrUbiquitousTech 4 жыл бұрын

Great video, thanks for sharing! I'll be changing my reverse synchros someday soon, this'll help.

@javiersernan9310 4 жыл бұрын

Excellent Work and Video, Very detail oriented and knowledgeable, Congratulations for your Achievement!

@charlesonyango5608 3 жыл бұрын

Thanks so much for this. Picked up one just like yours today. Looking forward to this. Your video will be a big help.

@Bemaritohtori 4 жыл бұрын

Just in case you might actually loose a bearing ball like in this video; you can actually go to a shop that sells bearings and get a ball with the needed dilensions if they happen to have them in stock👍🏻

@sethwoot 2 жыл бұрын

Anyone else feel like this guy is being specious in that he has done this before? I mean good lord

@TattsForLife 4 жыл бұрын

Best zf video I watched so far

@sixrrrsixrrr2040 3 жыл бұрын

Great video. Extremely helpful. I’m about to buy a used one. This assisted in making my decision. Thank you for this. 👍🏻

@packjoe2004 4 жыл бұрын

Good timing, my S5-42 needs rebuilt, now I may do this myself...THANKS!!!

@hodgie542 2 жыл бұрын

Great job! You did a good job of Showing this in detail thanks look forward to more videos

@glennramsey917 3 жыл бұрын

Buddy you sure do have it going on ..i really like how your not working in a profesional shop but in the floor ..it shows ppl you can fix it anywhere lol ...btw thanks for the video im sure it will come in handy ..i just put a zf5 in my 77 f100 swb with a 460 in it with 175 shot of nitrous ..im just building a fun truck to cruise around in on weekends .. btw i love one of your wall decorations behind your lil oven ..lol

@santiagohernandezsuazo8374 8 ай бұрын

Great video and job. You did explain details at all.

@GravvyTrain Жыл бұрын

Helpful video. I got everything rebuilt, but I got stuck because my case halves are shimmed out ~1/8". Now I've got to get that special puller to get the race out and buy another oil baffle. Basically, I thought I'd get lucky and use the old shims without doing all the fancy measurements.

@stek96 2 жыл бұрын

This is a great video, thanks for this, I will repair this box for the 7.3 motor.

@TheShockwaveDragon 10 ай бұрын

Mordecai (Regular Show) overhauls an F-350 transmission. You sound just like him!

@guol1806 2 жыл бұрын

The three jaw puller wasn’t long enough. Resorted to the concrete method for disassembly. Thank you for the video.

@narmale 4 жыл бұрын

HAHAHA, have you been watching This Old Tony much? xD thank you so much for this video, im about to start my zf5 this week, this will be much watched... and yes, I bought a set of heavy snap ring pliers from snap-on just for this job :P

@itsalwaysfriday9766 3 жыл бұрын

Great video.

@paulomoraes6476 3 жыл бұрын

Parabéns pelo vídeo muito bem explicativo me ajudou bastante

@wayoutwest4944 4 жыл бұрын

Good job.

@sk8rboy9711 4 жыл бұрын

This video deserves so much more credit

@WhiteLightning79 2 жыл бұрын

Do I have to pull everything out to change a shift fork, or can I just pull out the shifting rods

@jaydenhill3837 2 жыл бұрын

My zf5 is stuck in first gear. Do you have any tips on how to maybe fix it with out having to rebuild it.

@MILLY10p 2 ай бұрын

We just put a rebuilt one in ours and it won't shift. We did a new clutch. Did the fluid too. Any ideas ?

@wallyworld6249 4 жыл бұрын

Very good video I really enjoyed it easy to follow along good detail I would only recommend to you wearing gloves when you're dealing with poisonous chemicals like you are

@luisenriquez5259 3 жыл бұрын

What’s was done at the machine shop besides a good wash

@pcwizzy460 2 жыл бұрын

I need to rebuild my ZF S5-42 in my 1991 F-250 4x4. My trans grinds and clunks into gear sometimes when releasing clutch when I already have my hand off of the shifter. And it'll clack with every clutch release in gear, And going to engine brake off of the gas it does the same clack, and letting off the gas in reverse does a loud CAKLUNK.

4 жыл бұрын

Good good good job 👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏👏exelent!!!!!!

@boroda_customs9861 2 жыл бұрын

hi what manual transmission will fit 351 windsor '94

@procopioferreira7973 2 жыл бұрын

Qual a temperatura que deve esquentar o rolamento?

@hhn2002 3 жыл бұрын

Bravo 👍

@kaifray5736 2 жыл бұрын

Great video, how do these gearboxes hold up in a pickup truck?, i have one lying around in my workshop wich i want to install behind my 12v cummins

@cannoncolossus2449 2 жыл бұрын

They’re generally regarded as a strong transmission and rated around 460 ft/lbs. It will handle a stock 12v Cummins.

@K.a.z.i.m-I.v.a.n.o.v_ 3 жыл бұрын

Видео супер.Всё подробно и понятно. Еще бы по-русски говорили, тогда было бы вообще супер.

@rileyann2748 5 ай бұрын

my 1995 1st. 2nd. gear syncro sleeve has no three sets of three teeth, the are all the same. its like that on the 47. i ordered one and its the same. anyone else run into this. help

@BreastMilkBandit 4 жыл бұрын

54:55 that noise does that happen when you lug the engine a little?

@TheFenderman 3 жыл бұрын

Yes, I've had the exact same trans for years and they are long gears (Hence the "fun" between 2nd and 3rd at 30mph). I found that especially in traffic it's like there's no sweet spot, you either go all the way to 2500-2700 or you'll hear that sweet ERRGH every time. Doesn't seem to hurt them much but being careful drivers it causes some concern for sure.

@johnholmes1401 Жыл бұрын

Would you mind reposting that pdf. That would be awesome

@dokterkarel 2 жыл бұрын

19:31 diner's ready!

@SupaSwope 4 жыл бұрын

can you link or show name of the big jaw puller you bought for $40?

@TheRedneckStig 4 жыл бұрын

Here is a similar product: amzn.to/2DihOk1

@corybodiker6243 Жыл бұрын

A how much would you charge to run me off a copy of that manual?

@zorro5620 4 жыл бұрын

hola me podrias decir que aceite lubricante lleva esa caja .gracias .

@Rafa_Ramirez733 4 жыл бұрын

zorro5620 esa transmisión lleva ATF de motorcraft

@zorro5620 4 жыл бұрын

@@Rafa_Ramirez733 graciass

@rm5643 9 ай бұрын

Здравствуйте! Помогите разобраться с расчетом оборотов на шестерне отбора мощности. КПП ZF s5-42 (5.72). Для того чтобы правильно подобрать КОМ и гидронасос мне необходимо знать количество оборотов, которое делает шестерня отбора мощности. Она находится на промежуточном вале. На ней 45 зубов на передаточном 5.72 и 43 зуба на передаточном 4.65. Я правильно понимаю, что она входит в зацепление с первичным валом, с той его частью на которой 27 зубов на передаточном 5.72 и 29 зубов на передаточном 4.65? Тогда при 1000 оборотов мотора на ней будет 600 оборотов на передаточном 5.72 и 670 оборотов на передаточном 4.65? или нет? Спасибо!

@kennethcravens125 Жыл бұрын

Did nogalitos ever tell you what differential these shims came from? I know its been a good long while, but ive been trying to guesstimate online what diff shims to use and found this video.

@TheRedneckStig Жыл бұрын

I don't remember. Maybe a Ford 8.8 but don't take my word. I'd call them or talk to your local transmission parts dealer and see what they have.

@kennethcravens125 Жыл бұрын

@@TheRedneckStig Thanks man i appreciate it. Happy holidays!

@glennramsey917 3 жыл бұрын

Aha !!! You said it makes noise before and it makes noise now .. thats good news mine makes noise too ..im gonna bolt my slicks on and fill up my nitrous botttle and just send it !!!!

@jaredlindstrom7618 3 жыл бұрын

If you over fill it by a quarter or half a quart it quiets it down

@glennramsey917 3 жыл бұрын

@@jaredlindstrom7618 I may have to try that just because why not ..I run the truck on nitrous a while back for a pull or 2 now it seems to be a lil louder .

@jaredlindstrom7618 3 жыл бұрын

Zfs are just noisy when I swapped mine in years ago it was noisy like that, came across this overfill method and it's been quiet for years. Just no more than half a quart

@aleksandarderajic47 4 жыл бұрын

Hello, great video. I have similar problem and I hope that You can help me. I have truck with bad gearbox, gearbox is ECOLITE S6-36 1290 052 387. Do You have service manual for this gearbox, it wolud me help a lot. Thank You in advance

@Angel-xe2de 4 ай бұрын

Huh?? I thought all the f-150s got the Mazda m5od?

@rubenramos1000 2 жыл бұрын

Hello. you can activate substitutes in Spanish on your channel. good video good job.

@Jordan-bj7pw 4 жыл бұрын

for 1,000.00 would it be better just to buy the rebuilt one?

@makeitpay8241 4 жыл бұрын

no because you would not learn anything from buying a rebuild.

@codybosley400 4 жыл бұрын

You ain't buying a rebuilt zf5 for 1,000 hell a good case to rebuild worth 500 to 700

@Jordan-bj7pw 3 жыл бұрын

Idk. I bought a 351w with still bolted on zf5 that the guy said works good and has only 120,000 miles on it for 400.00.

@DS-Turbo 3 жыл бұрын

Try redline mtl oil 75w 80 weight

@WeisCarl2000 4 жыл бұрын

MAAAAAAAAAAAAAAAAAN This is miiiiint! I'm fixin to have to do this to my s47 shes screaming in 4th!

@makeitpay8241 4 жыл бұрын

if the future please buy a cheep harbor freight cart. i'm not talking about one with draws i'm talking about one of their 4 wheels carts that has lip that's about 3 inches high. they are great for putting things back together on. doing it on cardboard that's dirty already is going to bite you in the butt sooner or later. the rest of the video is great, keep at it.

@anthonyaviles8665 2 жыл бұрын

I installed one in a 1993 ford bronco

@Nice-lu4yb 2 жыл бұрын

Hello my name is Alex can you help me with a zf gearbox please

@billb.7184 3 жыл бұрын

All of a sudden I don't want to rebuild my trans myself...

@TheRedneckStig 3 жыл бұрын

Lol. If I can do it you can too

@anthonyaviles8665 2 жыл бұрын

That i also twin turbo it

@TheRedneckStig 5 жыл бұрын

Tools used in this video: Milwaukee Impact Gun: amzn.to/2ZlFPPE Milwaukee Drill: amzn.to/2KOTX00 Condiment Bottles: amzn.to/33QCkEk OTC Bearing Cup Puller: amzn.to/31Ub5ag 8" Gear Puller: amzn.to/2DihOk1 Anaerobic Gasket Maker: amzn.to/320Yan7

@loganjohnson2907 3 жыл бұрын

What was the rebuild kit that you purchased?

@pcwizzy460 2 жыл бұрын

F-150s should have an M5OD-R2...

@TheRedneckStig 2 жыл бұрын

Some F150s were optioned with the ZF, but you're right, the ZF was used mainly in the F250 and F350 trucks