ZF5 3rd gear grind problem - PowerStrokeNation : Ford Powerstroke Diesel Forum
 
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post #1 of 7 (permalink) Old 04-21-2015, 10:26 PM Thread Starter
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ZF5 3rd gear grind problem

Hey guys,
New to the forum just picked up a 96 5 speed stroker with 190k. The truck is immaculate but having one small problem. When the truck is cold going from 2nd-3rd gear it grinds. The truck has a brand new southbend with about 10k miles on it so I don't think the clutch is the issues. I am leaning twords the synchro being worn but the gear only grinds when shifting up not downshifting and also when I shift slow it will not grind. Once I have been driving around for a while and it warms up it will not grind anymore and goes into gear fine. I'm wondering if anyone has an idea on what it can be. I checked the pedal bushing and it is warn but I'm not sure if the tiny bit of play will have that much of an affect on the clutch. I was thinking about trying redline MTL as I have read it works good in some cases. Any help is appreciated. Thanks!!
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post #2 of 7 (permalink) Old 04-22-2015, 01:34 AM
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Re: ZF5 3rd gear grind problem

I would think its probably a synchro. I had an issue with mine where I couldn't downshift into second. I could go from 1st to 2nd with no issues though. I ended up breaking my shiftfork so i put new synchros in and now its fine. There's these little grooves on the inside of each synchro so that could be worn flat like some of mine were.

1995 F250 2wd, rebuilt zf5, T500 HPOP, South bend clutch, 3 into 4 inch exhaust, diy intake, diy ccv mod, diy IDM 140, riffraff ss hpx, D66, EBPV delete, DI Tunes, 160cc/stock.
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post #3 of 7 (permalink) Old 04-22-2015, 01:41 AM Thread Starter
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Re: ZF5 3rd gear grind problem

Dang not what I wanted to hear but oh well that's what I figured. I forgot to add the previous owner had it for almost 10 years and it has done it for a good portion of the time he said but never gotten any worse or better. Other than once it's warm. How hard is a syncro change? And if I'm going to do a syncro change should I just rebuild everything? Does the whole tranny need to be pulled for a rebuild or syncros or judge transfer case?
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post #4 of 7 (permalink) Old 04-22-2015, 10:35 AM
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Re: ZF5 3rd gear grind problem

Try to find a trans specialist so you can maybe get more info and possibly a confirmation on the problem. I hope I'm wrong about the synchro. But here is a link to a guy who rebuilts his zf5. ZF5 (S5-47) Rebuild - FSB Forums
I used this as a reference for when I rebuilt mine. I also printed out the actual manual for my trans which gives you the specific clearances for installing.

1995 F250 2wd, rebuilt zf5, T500 HPOP, South bend clutch, 3 into 4 inch exhaust, diy intake, diy ccv mod, diy IDM 140, riffraff ss hpx, D66, EBPV delete, DI Tunes, 160cc/stock.
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post #5 of 7 (permalink) Old 04-27-2015, 12:43 AM
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Re: ZF5 3rd gear grind problem

Could also be an input shaft bearing. Mine was doing what you describe and replacing the input shaft and bearing fixed it.

96 F350 CCLB SRW, tymar, 4in turbo back, beans 6 pos, stock inj, banks intercooler, zf5 w/ 4.10s, 37gal rear tank, 285s. Tows horses around KY.
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post #6 of 7 (permalink) Old 04-29-2015, 08:07 PM
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Re: ZF5 3rd gear grind problem

If you're going to pull the transmission for new symchros, I'd do bearings and all.

I'd try fresh fluid first.

2000 F-350 4x4, 7.3L/6 Speed.
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post #7 of 7 (permalink) Old 05-03-2015, 05:46 AM
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Re: ZF5 3rd gear grind problem

Try fresh fluid first specifically Redline MTF and iirc 4quarts.

jrc

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