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  #1  
Old 12-25-2010, 08:52 PM
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replacing ZF5

replacing my ZF5 and new clutch today. anyone have any little tips to help me out?
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  #2  
Old 12-25-2010, 09:31 PM
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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
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  #3  
Old 12-25-2010, 09:39 PM
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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.
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  #4  
Old 12-25-2010, 10:28 PM
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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.
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  #5  
Old 12-25-2010, 10:56 PM
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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
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  #6  
Old 12-26-2010, 03:25 AM
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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?
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  #7  
Old 12-26-2010, 03:33 AM
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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.
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Old 12-26-2010, 03:35 AM
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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.
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Old 12-26-2010, 03:35 AM
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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.
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  #10  
Old 12-26-2010, 01:27 PM
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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
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