replacing ZF5 - PowerStrokeNation : Ford Powerstroke Diesel Forum
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 16 (permalink) Old 12-25-2010, 08:52 PM Thread Starter
BIG_RED
 
BIG_RED's Avatar
 
Join Date: Nov 2009
Location: Humboldt County
Posts: 280
replacing ZF5

replacing my ZF5 and new clutch today. anyone have any little tips to help me out?

1996 F250:
-5spd w/4.10's
-3" dp to 4" straight pipe
-SouthBend ConOFE clutch
-K&N cone filter
-EBPV brake
-ISSPRO Gauges
-Custom E-Fuel
-Dana 60
-And now a custom front right fender.......
BIG_RED is offline  
Sponsored Links
Advertisement
 
post #2 of 16 (permalink) Old 12-25-2010, 09:31 PM
Senior Veteran Member
 
Centxdiesel's Avatar
 
Join Date: Feb 2009
Location: Georgetown, Texas
Posts: 935
Re: replacing ZF5

Take your time, and assess everything before starting. PB Blaster on bolts/nuts ahead of time helps. Remove exhaust, remove drive shaft, remove tranny, remove clutch.
Clutch in less than 3Hrs-Single mass conversion pictures from trucks photos on webshots

Centxdiesel
1997 F250 XL SC, 445HP 886TQ,
30% nozzle Hybrids from Nate@ unlimiteddiesel.com,
Adrenaline, Beans D-66,Beans E-Fuel,Valair Ceramic-Kevlar clutch.

Awesome Tuning by: Matt: from: gearheadautomotiveperformance.com
Centxdiesel is offline  
post #3 of 16 (permalink) Old 12-25-2010, 09:39 PM
Shortbus driver
 
u2slow's Avatar
 
Join Date: Nov 2007
Location: Salt Spring Island, BC
Posts: 223
Re: replacing ZF5

The shop that did my clutch loosens the cab mounts and shoves in 2x4 chunks as spacers to get the room he needed.


'93 F250 2wd, 7.3IDI/5spd/4.10
'89-93 Dodge CTD jalopies
u2slow is offline  
post #4 of 16 (permalink) Old 12-25-2010, 10:28 PM
Boost Gets You Laid
 
Join Date: Nov 2009
Location: Havelock, NC/ Columbus, OH
Posts: 160
Re: replacing ZF5

If your not using a lift, I found it really helpful to use two floor jacks (one underneath the trans and one under the t-case) to position the whole thing back up onto the engine. I didnt remove my t-case though. I was able to replace my clutch with a friend in about 2.5 hours. Just did it in a storage unit so we were limited to about a foot on each side of the truck. No serious tricks needed for the project. A little messing with the shifter to get it to clear but didnt take more than 2 minutes.

1997 F-350 7.3L
Hypermax Intercooler, DIY intake, RDS Stage 2s, Bob Rileys(CPR fuel system, HPOP Crossover, Coolant Filter) SouthBend Dual Disc clutch, TW custom tunes, Farmboys full 4", 17* HPOP,
1997 Jeep Cherokee
2004 Land Rover Discovery
1985 Mercedes 300 Turbo Diesel
2001 Sterling Silver Star
2005 Volvo VNT64T660
RCPro87 is offline  
post #5 of 16 (permalink) Old 12-25-2010, 10:56 PM
PSN Local
 
radcustoms's Avatar
 
Join Date: May 2009
Location: Morrisville, PA
Posts: 358
Re: replacing ZF5

When i changed mine it was really hard to get the top bolts. so here is what i did marked where the bolts were and trimmed it up with a dremel. that way i can get a socket in there better. some guys pull up the carpet and pull the inspection cover to get the top bolts.But thats to much work for me. Its a pain to get them out but once u go to put them back in its so worth it, and for next time u go to do the clutch.
here is a pic

95 F-250 4x4 standard cab, under construction PULLER
97 F-250 4x4 ex. cab short bed. Daily driver
radcustoms is offline  
post #6 of 16 (permalink) Old 12-26-2010, 03:25 AM Thread Starter
BIG_RED
 
BIG_RED's Avatar
 
Join Date: Nov 2009
Location: Humboldt County
Posts: 280
Re: replacing ZF5

so i got all the linkage and hydraulics and drive shafts disconnected. was going to use an atv jack to lift it and the t case but wouldnt you know, it doesnt go high enough and it has a support bar that wont clear the t-case. looks like im down for the night til i can find a real tranny jack. should i just take the t case off seperately?

1996 F250:
-5spd w/4.10's
-3" dp to 4" straight pipe
-SouthBend ConOFE clutch
-K&N cone filter
-EBPV brake
-ISSPRO Gauges
-Custom E-Fuel
-Dana 60
-And now a custom front right fender.......
BIG_RED is offline  
post #7 of 16 (permalink) Old 12-26-2010, 03:33 AM
PSN Veteran
 
Join Date: May 2009
Posts: 797
Re: replacing ZF5

You won't need to remove the xfer case with a real transmission jack. Just be sure to strap the transmission onto the jack very securely so it won't roll or move around on you.

'94 F250 supercab 4x4, original owner, 4.10LS, DIY elec fuel, Tymar air, Beans tunes on VA 4 position chip, Adrenaline HPOP, VDO boost/pyro/outside temp gauges, Ford digital AIC, DPPI downpipe, gutted EBPV, modded turbo ped, Con OFE, add-a-leafs front/rear, Monroe Reflex shocks, Milemarker 449SS hubs...coming soon: 6.0 IC...wish list: Stage 2's
nashvillebill is offline  
post #8 of 16 (permalink) Old 12-26-2010, 03:35 AM
PSN Local
 
radcustoms's Avatar
 
Join Date: May 2009
Location: Morrisville, PA
Posts: 358
Re: replacing ZF5

Quote:
Originally Posted by BIG_RED View Post
so i got all the linkage and hydraulics and drive shafts disconnected. was going to use an atv jack to lift it and the t case but wouldnt you know, it doesnt go high enough and it has a support bar that wont clear the t-case. looks like im down for the night til i can find a real tranny jack. should i just take the t case off seperately?
U could take the T-case off makes it a little lighter. And alot easier to work with when u gotta line up the spline with the pilot bearing and the inside of the new clutch. Thats how i did mine it was fun had to get in there with a mirror to see if it was lined up. I have heard of guys pulling them down and installing them with a floor jack to.If u have someone else to help u balance it.

95 F-250 4x4 standard cab, under construction PULLER
97 F-250 4x4 ex. cab short bed. Daily driver
radcustoms is offline  
post #9 of 16 (permalink) Old 12-26-2010, 03:35 AM
PSN Veteran
 
salprofish's Avatar
 
Join Date: Feb 2010
Location: Alpena, Arkansas
Posts: 969
Re: replacing ZF5

Quote:
Originally Posted by BIG_RED View Post
so i got all the linkage and hydraulics and drive shafts disconnected. was going to use an atv jack to lift it and the t case but wouldnt you know, it doesnt go high enough and it has a support bar that wont clear the t-case. looks like im down for the night til i can find a real tranny jack. should i just take the t case off seperately?
The guys at BTS take the tc off.

97 250 EC 4x4
5 speed
6637 Napa Filter
ccv mod
3" diamond eye dp
175cc 80% over Rosewood inj.
Custom tuning by Cale Thompson

4" Rough Country Lift
315-70-17 BFG AT Tires
Rebuilt zf5 at 250000
my new favorite gun:
LAR grizzly 50 BMG big boar
salprofish is offline  
post #10 of 16 (permalink) Old 12-26-2010, 01:27 PM
STILL LEARNING
 
Bradbilt's Avatar
 
Join Date: Oct 2008
Location: Gilbert PA
Posts: 18,038
Re: replacing ZF5

Take the t-case off. It is 6 bolts and make the trans alot more managable and 150lbs lighter

if you cant find a jack to go high enough, just take your tires off and let the Ball joints sit on 2x4s and your rear shock mounts sit on 6x6s

Looking for Blue 40-20-40 seat for OBS. PM me if any known
Bradbilt is offline  
Reply
Gear in this thread - Powered by O'Reilly Auto Parts

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the PowerStrokeNation : Ford Powerstroke Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome