Go Back   Ford Truck Enthusiasts Forums > Diesel > 1999 - 2003 7.3L Power Stroke Diesel
Sign in using an external account
Register Forgot Password?


1999 - 2003 7.3L Power Stroke Diesel SPONSORED BY:

ZF6 problem with 2nd gear

Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
  #1  
Old 11-29-2010, 06:09 PM
camodown's Avatar
camodown camodown is offline
Posting Guru
 
Join Date: Mar 2008
Location: West Tx
Posts: 1,104
camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.
ZF6 problem with 2nd gear

Hope everyone had a great Thanksgiving! Been a little while since I have posted, and was hoping I wouldn't have to post problems with the newly swapped trans but oh well. I have just started having issues with going from 1st gear (Not L), to 2nd gear. I will go to downshift from 3rd to second and when I let the clutch out the engine drops to idle and it seems to be in neutral but it feels like it is in gear shifter feel wise. Now sometimes if I don't hit the 1st to 2nd gear just right, it does the same thing; just goes into neutral it seems. If I pull the lever down and right slightly it will go into gear occasionally. The shifter seems to have a lot of slop so I am hoping it is just an adjustment. Fluid levels are fine... Has anybody seen or heard of anything like this?

Just for clarification, I am using the gears L,1,2,3,4,5,6 as opposed to L being 1.
__________________
2002 F-350 Powerstroke 4x4 Crew Long bed All black Lariat custom Cobra cb mount, 05 Mirrors, ZF6 mod, Manual Transfer Case
Reply With Quote
  #2  
Old 11-29-2010, 07:19 PM
F350-6's Avatar
F350-6 F350-6 is offline
Post Fiend
 
Join Date: Mar 2007
Location: Texas
Posts: 24,651
F350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputation
No grinding?

Sounds like an adjustment or something loose in the shift lever or fork. Pull it apart from inside the cab and let us know what you see. (Remember we like pics)
__________________
Chris
2002 F350 6-speed 444 CID. XLT, Heated Seat, 500,000 & counting.
Reply With Quote
  #3  
Old 11-29-2010, 07:22 PM
TinyWonder's Avatar
TinyWonder TinyWonder is online now
Posting Guru
 
Join Date: Jun 2010
Location: Oregon City, Oregon
Posts: 2,420
TinyWonder is a splendid one to beholdTinyWonder is a splendid one to beholdTinyWonder is a splendid one to beholdTinyWonder is a splendid one to beholdTinyWonder is a splendid one to beholdTinyWonder is a splendid one to beholdTinyWonder is a splendid one to behold
I sure hope that you can figure out what is causing your troubles. I had my own problems with my ZF6 this past year. Unfortunatly, just about the only way to diagnose what the problem requres someone tearing down the transmission to inspect things down to the molecular level.

My issue was similar in that it was hard to shift between first and second (on the same rail in the transmission). Mine turn out to be a cracked cyncromesh gear.

Good luck.
__________________
Tiny,

2001 F350, CC, Lariat, 4x4, SRW, 7.3 PSD, long bed, 6 speed, K & N intake and filter, air bags, Powerslot rotors, Hawk LTS pads, Energy Suspension front sway bar bushings, foil delete, Moog ball joints, HPX, FRX, RiffRaff boots and plenum inserts, AIH delete, factory rear sway bar, Marinco plug. 110K
Reply With Quote
  #4  
Old 11-29-2010, 07:55 PM
Fat Diesel's Avatar
Fat Diesel Fat Diesel is offline
Postmaster
 
Join Date: Aug 2005
Location: Morgan Hill, CA
Posts: 2,924
Fat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to behold
Sounds like something related to the shifting. If it were the syncro's then you'd have hard shifting and grinding trying to get the shifter lever into it's position.

I have my old ZF6 in the garage so I took a few pics for the 'hood to see what is what in the interface between the shifter and transmission.

Looking straight down where the shifter bolts on.
Click the image to open in full size.
.
Close up from the drivers side.
Click the image to open in full size.
.
The business end of the shifter.
Click the image to open in full size.
.
And, uh... we'll just call this one big Jim and the twins.
Click the image to open in full size.
__________________
2014 Fusion Energi
Early 99 F250 PSD 4x4 CC 6spd Common Mods 300,000+ Miles, No longer driven daily
1964 Falcon Convert 289 Toploader 9" 4 Wheel Disks
Nov '10 Recipient: "dedicated report-back tech thread poster" award!
Reply With Quote
  #5  
Old 11-29-2010, 08:49 PM
camodown's Avatar
camodown camodown is offline
Posting Guru
 
Join Date: Mar 2008
Location: West Tx
Posts: 1,104
camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.
Well I seemingly lucked out in a sense and also not. The roll pin holding the shift selector on was 90% out of it's slot almost ready to drop into the trans and cause major damage. BUT, now, the shift selector is not aligned with the rail which has a large amount of tension to keep the shift lever centered in N, and I have a roll pin which I have no idea where to find, nor do I know how I am going to install it. Any ideas?
__________________
2002 F-350 Powerstroke 4x4 Crew Long bed All black Lariat custom Cobra cb mount, 05 Mirrors, ZF6 mod, Manual Transfer Case
Reply With Quote
  #6  
Old 11-29-2010, 08:50 PM
camodown's Avatar
camodown camodown is offline
Posting Guru
 
Join Date: Mar 2008
Location: West Tx
Posts: 1,104
camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
__________________
2002 F-350 Powerstroke 4x4 Crew Long bed All black Lariat custom Cobra cb mount, 05 Mirrors, ZF6 mod, Manual Transfer Case

Last edited by camodown; 12-01-2010 at 08:07 PM. Reason: Re link pics
Reply With Quote
  #7  
Old 11-29-2010, 08:58 PM
Fat Diesel's Avatar
Fat Diesel Fat Diesel is offline
Postmaster
 
Join Date: Aug 2005
Location: Morgan Hill, CA
Posts: 2,924
Fat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to behold
Man that pin has a nasty crack. Get a new pin- are you close to a big city with an industrial supply store? Doubt the dealer would stock this but might.

You might try tying some wire around the piece and the other end around a bar or something. Also maybe vice grips with a T shirt or something to keep from scarring any parts...
__________________
2014 Fusion Energi
Early 99 F250 PSD 4x4 CC 6spd Common Mods 300,000+ Miles, No longer driven daily
1964 Falcon Convert 289 Toploader 9" 4 Wheel Disks
Nov '10 Recipient: "dedicated report-back tech thread poster" award!
Reply With Quote
  #8  
Old 11-29-2010, 08:58 PM
F350-6's Avatar
F350-6 F350-6 is offline
Post Fiend
 
Join Date: Mar 2007
Location: Texas
Posts: 24,651
F350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputationF350-6 has a superb reputation
Why does the mounting flange on your housing look cracked?

Got any big needle nose to push the roll pin back in place?
__________________
Chris
2002 F350 6-speed 444 CID. XLT, Heated Seat, 500,000 & counting.
Reply With Quote
  #9  
Old 11-29-2010, 09:31 PM
camodown's Avatar
camodown camodown is offline
Posting Guru
 
Join Date: Mar 2008
Location: West Tx
Posts: 1,104
camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.
I am hoping the roll pin isn't anything fancy so I can find it locally. The cast looks cracked probably because of the mating surfaces on the shift tower cap which aren't machined all that great.
__________________
2002 F-350 Powerstroke 4x4 Crew Long bed All black Lariat custom Cobra cb mount, 05 Mirrors, ZF6 mod, Manual Transfer Case
Reply With Quote
  #10  
Old 11-29-2010, 09:49 PM
camodown's Avatar
camodown camodown is offline
Posting Guru
 
Join Date: Mar 2008
Location: West Tx
Posts: 1,104
camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.
Hey those pictures above, your right and left shift rails don't line in a straight line like mine do. Is that unit in 4th gear? Do your shift rail indentations line up in N?

Thanks guys for the fast replies! I will try to get the roll pin ASAP and use some long needle nose pliers to install the new pin.
__________________
2002 F-350 Powerstroke 4x4 Crew Long bed All black Lariat custom Cobra cb mount, 05 Mirrors, ZF6 mod, Manual Transfer Case
Reply With Quote
  #11  
Old 11-29-2010, 10:15 PM
Fat Diesel's Avatar
Fat Diesel Fat Diesel is offline
Postmaster
 
Join Date: Aug 2005
Location: Morgan Hill, CA
Posts: 2,924
Fat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to behold
Yup. It's in 4th for re-install if it ever comes to that since I have a new one on the way. Since that is the direct drive gear it makes it easy to line up the splines- just turn output shaft a little and clutch alignment is much improved.
__________________
2014 Fusion Energi
Early 99 F250 PSD 4x4 CC 6spd Common Mods 300,000+ Miles, No longer driven daily
1964 Falcon Convert 289 Toploader 9" 4 Wheel Disks
Nov '10 Recipient: "dedicated report-back tech thread poster" award!
Reply With Quote
  #12  
Old 12-01-2010, 07:59 PM
camodown's Avatar
camodown camodown is offline
Posting Guru
 
Join Date: Mar 2008
Location: West Tx
Posts: 1,104
camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.camodown has a great reputation on FTE.
UPDATE:

Well, I have no faith in roll pins or slot pins anymore. After seeing this one cracked, I will definately be shifting very gently from now on. I bet the fracture came from when a tree fell on the donor truck though and probably hit the shifter, but I have no idea.

Here is how I fixed it if anyone notices a change in shift feel. It is such an easy check, I will periodically be popping the cover off to make sure the pin isn't walking out again....

Click the image to open in full size.
Here is the PN

Click the image to open in full size.
Here are the two side by side. The fractured one had definately lost its springiness

Click the image to open in full size.
Click the image to open in full size.
I rotated the shifter driver sideways and using a magnetic multi tool, drove the pin in far enough so it would hold itself in by friction. I don't have a picture of the pin, but it is just sticking out of the driver. Don't drive the pin in too hard or far, as you will need to line the pin up with the index mark on the center rail seen in the picture.

Click the image to open in full size.
Click the image to open in full size.
Then I used some 3/4" drive extensions to hold the shift driver tower so when I pryed on the pin using my spare tire hubcap remover it wouldn't damage anything or pop out of gear.

Click the image to open in full size.
As the pin was pushed in further and further, I then used a bunch of 3/4" extensions to use the flat side to push the remainder of the pin in. It takes some hammering on the extensions to seat the pin all the way.

Click the image to open in full size.
The best vantage point is with the assembly in L, or Low gear


For extra security, I noticed that ZF prescribes doing a double pin, so in other words, 'sleeving' the larger pin with a smaller one. Obviously I did not do this.

I noticed immediately the shift pattern, especially L,R,1,2 was less mushy feeling and much more precise which is good. I was really lucky to find the pin almost ready to drop in the trans and chew everything up....




I am curious though Fatdiesel, if you have a chance, could you put the spare trans you have in L, and use a mirror and see if ZF did indeed sleeve the driver roll pin with a smaller one inside? If you don't have time, no big deal!
__________________
2002 F-350 Powerstroke 4x4 Crew Long bed All black Lariat custom Cobra cb mount, 05 Mirrors, ZF6 mod, Manual Transfer Case

Last edited by camodown; 12-01-2010 at 08:04 PM. Reason: Pics
Reply With Quote
  #13  
Old 12-01-2010, 08:40 PM
Kwikkordead's Avatar
Kwikkordead Kwikkordead is offline
Post Fiend
 
Join Date: Jun 2004
Location: North Seattle, WA.
Posts: 22,220
Kwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputationKwikkordead has a superb reputation
http://www.facebook.com/http://facebook.com/Kwikkordead#!/Kwikkordead
Subscribing for the pictures.
Glad you got if fixed so easily.
__________________
Dan
1999 F550 4x4 ZF6 pulling a Cedar Creek 36RLTS. Lotta mods.
1999 VW Jetta TDI 5speed stick, Titan 520's, CCV, EGR, CAT.
2000 VW Passat 1.8t Tiptronic. ZZOOOOOMMMM!!!
You cannot explain or explain away the power of God.
Reply With Quote
  #14  
Old 12-02-2010, 11:05 AM
Fat Diesel's Avatar
Fat Diesel Fat Diesel is offline
Postmaster
 
Join Date: Aug 2005
Location: Morgan Hill, CA
Posts: 2,924
Fat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to behold
Quote:
Originally Posted by camodown View Post
I am curious though Fatdiesel, if you have a chance, could you put the spare trans you have in L, and use a mirror and see if ZF did indeed sleeve the driver roll pin with a smaller one inside? If you don't have time, no big deal!
I'm at work right now but I'll try to do that. Do you know the history of your ZF6? My gut reaction when seeing what was up with yours is someone had a good grip on the shifter when crashing the truck and put a lot of force on it.
__________________
2014 Fusion Energi
Early 99 F250 PSD 4x4 CC 6spd Common Mods 300,000+ Miles, No longer driven daily
1964 Falcon Convert 289 Toploader 9" 4 Wheel Disks
Nov '10 Recipient: "dedicated report-back tech thread poster" award!
Reply With Quote
  #15  
Old 12-02-2010, 10:49 PM
Fat Diesel's Avatar
Fat Diesel Fat Diesel is offline
Postmaster
 
Join Date: Aug 2005
Location: Morgan Hill, CA
Posts: 2,924
Fat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to beholdFat Diesel is a splendid one to behold
Yep it has a another pin inside the roll pin.

I'll shoot a pic of my ZF6 when I get it and see what they're doing on the new ones.
.
.
Click the image to open in full size.
__________________
2014 Fusion Energi
Early 99 F250 PSD 4x4 CC 6spd Common Mods 300,000+ Miles, No longer driven daily
1964 Falcon Convert 289 Toploader 9" 4 Wheel Disks
Nov '10 Recipient: "dedicated report-back tech thread poster" award!
Reply With Quote
Old 12-02-2010, 10:49 PM
 
 
 
Reply


Similar Threads
Thread Thread Starter Forum Replies Last Post
stuck in gear fisher4life Clutch, Transmission, Differential, Axle & Transfer Case 3 09-30-2014 09:28 AM
E4OD Shifter linkage problem? Toplait 1987 - 1996 F150 & Larger F-Series Trucks 29 08-20-2014 03:03 PM
Shift pattern not right on 02 6-speed 7.3l Viper9087 Clutch, Transmission, Differential, Axle & Transfer Case 2 02-18-2013 11:57 PM
3 on the tree problem Ratt617 1961 - 1966 F-100 & Larger F-Series Trucks 25 03-17-2010 02:38 PM
F150 Mazda manual hard shift and grinding zach_barrow Clutch, Transmission, Differential, Axle & Transfer Case 6 02-04-2008 10:10 PM


Go Back   Ford Truck Enthusiasts Forums > Diesel > 1999 - 2003 7.3L Power Stroke Diesel

Tags
2001, 2nd, fix, ford, gear, grind, hard, pin, pins, powerstroke, problems, roll, shift, zf, zf6

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not 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 On
Trackbacks are On
Pingbacks are On
Refbacks are On

Forum Jump


Participate In The Forums

Create new posts and participate in discussions. It's free!

Sign Up »


All times are GMT -5. The time now is 01:04 AM.


Powered by vBulletin® Version 3.8.7 AC1
Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Advertising - Terms of Use - Privacy Statement - Jobs
This forum is owned and operated by Internet Brands, Inc., a Delaware corporation. It is not authorized or endorsed by the Ford Motor Company and is not affiliated with the Ford Motor Company or its related companies in any way. Ford® is a registered trademark of the Ford Motor Company.

vbulletin Admin Backup