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post #1 of 11 (permalink) Old 04-13-2016, 02:12 AM Thread Starter
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zf5 grinding gears

A few months ago I swapped from auto to a s47 zf5. The zf had 300k on it and has been grinding from the 2-3 up shift and the 3-4 down and 3-2 down since I installed it. I have put 7k miles on it like this being carful to shift real slow on the 2-3 and 4-3 but it is basically impossible to shift into 2nd over 5mph. Before I drop a bunch of cash on a reman is there anything to check like clutch master/slave to make sure it is all working proper? Everything feels good to me. I put in a new pre bled master/slave cylinder when I did the swap. I am thinking about rebuilding myself if you think new syncros, bearings, rings, ect is all it needs. How hard of job is it? Special tools needed?
Thanks

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PSD. CC 4X4 195K, IDM mod, 6 Leaker IC, DP Tuner 6pos chip, WOP QSSB Turbo, kit by Carson Stauffer. Swamps 175/146's sticks, CNG kit 35mpg's on the diesel, E-fuel, Adrenaline and converted to a ZF5. RSK rolling on 35's. 4" straight pipe. 2011 f350 ccsb leveled on 35's, I can neither confirm nor deny that it is tuned and deleted!
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post #2 of 11 (permalink) Old 04-13-2016, 02:44 AM
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Re: zf5 grinding gears

Sounds like the sychros are just bad.
You could try changing the fluid, but no guarantees.
Also when you downshift, Rev the engine a little.

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post #3 of 11 (permalink) Old 04-13-2016, 02:47 AM
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Re: zf5 grinding gears

Do you have trouble getting it in 1st or reverse? What brand master?

01 f-250, Standard
Rev tech 4" lift, 37" military wrangler Mt tires
KC diy 66, Full force 160/100 and custom tunes from PHP
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post #4 of 11 (permalink) Old 04-13-2016, 03:13 AM Thread Starter
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Re: zf5 grinding gears

Quote:
Originally Posted by 79jasper View Post
Sounds like the sychros are just bad.
You could try changing the fluid, but no guarantees.
Also when you downshift, Rev the engine a little.
I put new fluid in it from the start and has done it from the start of the swap. Tried the revving and it doesn't help either.

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Quote:
Originally Posted by Sbluke55 View Post
Do you have trouble getting it in 1st or reverse? What brand master?
No, seems fine but I am always stopped. It smoothly goes into all gears when stopped. Dorman brand.
Should I try bleeding it? It feels good....atleast I think it does.

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PSD. CC 4X4 195K, IDM mod, 6 Leaker IC, DP Tuner 6pos chip, WOP QSSB Turbo, kit by Carson Stauffer. Swamps 175/146's sticks, CNG kit 35mpg's on the diesel, E-fuel, Adrenaline and converted to a ZF5. RSK rolling on 35's. 4" straight pipe. 2011 f350 ccsb leveled on 35's, I can neither confirm nor deny that it is tuned and deleted!
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post #5 of 11 (permalink) Old 04-13-2016, 03:44 AM
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Re: zf5 grinding gears

I know in the superduty the Dorman master cylinder rod is shorter than the oem rod.
Is there any play in the pedal bushings?
I just want to eliminate a disengagement issue before you drop money on a rebuild.

01 f-250, Standard
Rev tech 4" lift, 37" military wrangler Mt tires
KC diy 66, Full force 160/100 and custom tunes from PHP
Banks intercooler and full 4" exhaust, Diy S&B intake
Diy quad feed, Hydra, Isspro boost, pyro, and fuel pressure
3/0 battery cables with military style terminals
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post #6 of 11 (permalink) Old 04-13-2016, 03:50 AM Thread Starter
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Re: zf5 grinding gears

Quote:
Originally Posted by Sbluke55 View Post
I know in the superduty the Dorman master cylinder rod is shorter than the oem rod.
Is there any play in the pedal bushings?
I just want to eliminate a disengagement issue before you drop money on a rebuild.
Not much play. I actually adjusted the arm foreward to push the rod a little further to see if that helped....it didn't. I can adjust it further but then my cruise will not work. Also before I installed it the rod appeared to be the same as the stock one..

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PSD. CC 4X4 195K, IDM mod, 6 Leaker IC, DP Tuner 6pos chip, WOP QSSB Turbo, kit by Carson Stauffer. Swamps 175/146's sticks, CNG kit 35mpg's on the diesel, E-fuel, Adrenaline and converted to a ZF5. RSK rolling on 35's. 4" straight pipe. 2011 f350 ccsb leveled on 35's, I can neither confirm nor deny that it is tuned and deleted!
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post #7 of 11 (permalink) Old 04-13-2016, 07:06 PM
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Re: zf5 grinding gears

My ZF5 grinds from time to time. Has been for a couple of years. Run the correct synthetic oil it will help if you are not. I also overfill the ZF5 which also helped take care of the gear rollover a bit along with reducing the grinding shifts a little. It usually only happens when I am flying thru the gears and when cold.

97 250 7.3 Eaton VMP TVS, IDI performance T4 mount, S369SXE, my B code 350/200- my tunes- honey badger SR, Efuel, 5" SKY RSK TTB, BMW M3 seats, Toyo M/T
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post #8 of 11 (permalink) Old 04-13-2016, 07:47 PM Thread Starter
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Re: zf5 grinding gears

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Originally Posted by boostedretard View Post
My ZF5 grinds from time to time. Has been for a couple of yesxars. Run the correct synthetic oil it will help if you are not. I also overfill the ZF5 which also helped take care of the gear rollover a bit along with reducing the grinding shifts a little. It usually only happens when I am flying thru the gears and when cold.
I have the right fluid and mine does it worse when warm as the fluid warms up.

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PSD. CC 4X4 195K, IDM mod, 6 Leaker IC, DP Tuner 6pos chip, WOP QSSB Turbo, kit by Carson Stauffer. Swamps 175/146's sticks, CNG kit 35mpg's on the diesel, E-fuel, Adrenaline and converted to a ZF5. RSK rolling on 35's. 4" straight pipe. 2011 f350 ccsb leveled on 35's, I can neither confirm nor deny that it is tuned and deleted!
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post #9 of 11 (permalink) Old 04-13-2016, 10:36 PM
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Re: zf5 grinding gears

Also check the throw on your fork. My original fork was warped after putting a new one in the throw was about half as much. The original forks had tsb for being weak if I recall and the new fork was an updated one. I think. From the dealership the price was not that bad.

97 250 7.3 Eaton VMP TVS, IDI performance T4 mount, S369SXE, my B code 350/200- my tunes- honey badger SR, Efuel, 5" SKY RSK TTB, BMW M3 seats, Toyo M/T
54 GMC 453T
45 Chevy 451 diesel
51 Mack A51T
1916 Federal 1 1/2T
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post #10 of 11 (permalink) Old 04-13-2016, 11:00 PM Thread Starter
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Re: zf5 grinding gears

Quote:
Originally Posted by boostedretard View Post
Also check the throw on your fork. My original fork was warped after putting a new one in the throw was about half as much. The original forks had tsb for being weak if I recall and the new fork was an updated one. I think. From the dealership the price was not that bad.
I put a new fork in when I installed it but I will check it. Thanks
I called a local diesel shop and he quoted me $800 to rebuild it with new syncros, bearings, ect so I am going to do that. Before I even told him what it was doing he said "let me guess, 2nd and 3rd are grinding."
Trans shops wanted $1700- $2000 for a reman unit.

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PSD. CC 4X4 195K, IDM mod, 6 Leaker IC, DP Tuner 6pos chip, WOP QSSB Turbo, kit by Carson Stauffer. Swamps 175/146's sticks, CNG kit 35mpg's on the diesel, E-fuel, Adrenaline and converted to a ZF5. RSK rolling on 35's. 4" straight pipe. 2011 f350 ccsb leveled on 35's, I can neither confirm nor deny that it is tuned and deleted!
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