zf5 rear/tail housing 4x4 - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 12 (permalink) Old 09-13-2019, 06:21 PM Thread Starter
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zf5 rear/tail housing 4x4

Have a 2" +/- crack at top of rear tail housing, near the seam with the front case, on 1997 ZF S5-47. I have a few questions as I try to find a solution:

1. what tail housings are interchangeable? ZF s5-42 4x4? What about small blocks, or the big 460 gasser? I know the bell housing and gear ratios are different on the 460 transmissions, but not sure about the rear housing.

2. What are some ideas on short term fix in place? It is at the top of the housing, so only leaks when driving. Permatex, epoxy, solder (assuming I can get to it to solder)?

3. Any one have one to sell that will fit?

Thanks in advance for any input!

1997 F-250 7.3 PSD, 3" downpipe to 4" exhaust, EBPV delete (sort of, disconnected solenoid and wired open), Marty's efuel with fuel bowl delete, baby swamps injectors, D60 front axle, probably a few other things I cannot remember.
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post #2 of 12 (permalink) Old 09-13-2019, 07:42 PM
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Re: zf5 rear/tail housing 4x4

I had the same problem, I lived with it for a number of years until I decided to have it fixed. I took my transmission to a shop in Denver where they sourced a new tail shaft and replaced it for me.

Until then I just addded fluid once a month.

96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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post #3 of 12 (permalink) Old 09-14-2019, 12:15 AM
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Re: zf5 rear/tail housing 4x4

If it's not structural, I've patched with JB Quick weld, or the 2 part radiator epoxy works really well. Just be sure you get it CLEAN first so it sticks.

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post #4 of 12 (permalink) Old 09-14-2019, 02:42 AM
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Re: zf5 rear/tail housing 4x4

If you do try the above fix or if you find a tail housing check the mounts. That was my problem when I cracked mine

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96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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post #5 of 12 (permalink) Old 09-16-2019, 02:30 PM
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Re: zf5 rear/tail housing 4x4

I use these brazing rods around my garage known as HTS-2000. They have the ability to seal cracks up and holds stronger then ever before. Take a peak at this video, hell it may even be a permanent fix for your situation. The video is ridiculously funny but very informative.

Get out your pooper scoopers, cuz these suckas are talkin ####.
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post #6 of 12 (permalink) Old 09-16-2019, 04:15 PM
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Re: zf5 rear/tail housing 4x4

i have them aluminum brazing rods too. but i prefer to use the aluminum stick welding rods with the miller bobcat welder.
the brazing rods are good for thin stuff. anything more than 1/4 inch or so gets stick welded.

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post #7 of 12 (permalink) Old 09-16-2019, 04:46 PM Thread Starter
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Re: zf5 rear/tail housing 4x4

Thanks for all the responses. I did not have time to get into a proper fix because of the crack location it would require removing the transfer case at a minimum and probably the transmission itself, plus don't have a replacement part. Still looking for a replacement housing. For now I just covered the crack with black permatex sealant, just to stop some of the leaking (hopefully)!

Still looking for a housing if anyone has one.

I think the cause of the crack was the driveshaft bolts at the output shaft backed out after my son and his friend changed u-joints and probably did not put any loctite on the threads. Started vibrating on deceleration one morning and in the span of a short 10 miles the tranny was leaking.

Even if I find a replacement housing I plan to see about getting the existing one welded in case I need one in the future. Between my son, his friends, and me working on this thing itt is not a reach to think something like this could happen again!

1997 F-250 7.3 PSD, 3" downpipe to 4" exhaust, EBPV delete (sort of, disconnected solenoid and wired open), Marty's efuel with fuel bowl delete, baby swamps injectors, D60 front axle, probably a few other things I cannot remember.
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post #8 of 12 (permalink) Old 09-16-2019, 06:05 PM
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Re: zf5 rear/tail housing 4x4

Just a note: You might need to reset the shaft endplay to spec (correct sized shims???) if replacing the housing. Cheers!

97 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, Ext Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed

SOLD: 94 F350 CC DRW PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, 3Ē DP, Bilsteins, $12 AIC, Coolant Filter, Explorer O/H Console, Trans Temp, Boost, and Pyro, Pedestal Mod, Gutted EBPV
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post #9 of 12 (permalink) Old 09-17-2019, 03:39 PM Thread Starter
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Re: zf5 rear/tail housing 4x4

Quote:
Originally Posted by Patrick Feeley View Post
Just a note: You might need to reset the shaft endplay to spec (correct sized shims???) if replacing the housing. Cheers!

Thanks for that note/thought. I have no idea what the shaft endplay/shims is, but I plan to have a tranny shop do the housing replacement if/when I ever find one that is reasonably priced. Right now all I can find on ebay are in the $700-750 range. Of course "reasonable" becomes a different number depending on how well we are limping along (or not)!!

Thanks

1997 F-250 7.3 PSD, 3" downpipe to 4" exhaust, EBPV delete (sort of, disconnected solenoid and wired open), Marty's efuel with fuel bowl delete, baby swamps injectors, D60 front axle, probably a few other things I cannot remember.
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post #10 of 12 (permalink) Old 09-17-2019, 04:42 PM
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Re: zf5 rear/tail housing 4x4

Quote:
Originally Posted by cbsgcs View Post
Thanks for that note/thought. I have no idea what the shaft endplay/shims is, but I plan to have a tranny shop do the housing replacement if/when I ever find one that is reasonably priced. Right now all I can find on ebay are in the $700-750 range. Of course "reasonable" becomes a different number depending on how well we are limping along (or not)!!

Thanks
For another $500 you can have a whole transmission from a rebuilder.

96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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