1988 ZF transmission

[Rolando14]

hey guys, this is my first post on the site. seems like the neat/informative place to be... i have a 1988 F350 dump body, it has a zf s542 5 speed manual that is really not in good shape. All gears do not sound good at all, the only gear that sounds exceptional compared to the rest is 4th because I don't think it was used in the higher gears. i got the truck for $1,000 and it only has 33,300 miles on it. it was owned by a local cemetery. (lucky me) am i better off finding another ZF, or can i get away with rebuilding? i've heard the c6 won't work out because the truck has a pto... any response would be appreciated thanks

[Sycostang67]

You can usually get a used ZF for around $6-800. It would be the easiest thing to do.

[ArdWrknTrk]

Welcome to the FTE forums Rolando!

I had a 1960's Dodge dump with a slant 6 that came from a cemetery.
It had never been registered and had similar mileage.
The front end was shot from all the low speed turning it did.

On topic: The ZF 5-speed is a desirable gearbox.
Here is the troubleshooting guide link: http://www.zf.com/na/content/en/impo...ing_Guide.html

There are also the exploded view: http://www.zf.com/na/content/media/i...2_Exploded.pdf
And data sheet: http://www.zf.com/na/content/media/i...2datasheet.pdf

Without looking inside I don't think anyone could tell you whether you're better off rebuilding or exchanging it.
If you can find a bellhousing (you don't say which engine displacement) you do have the option of a Borg Warner T-19 4 speed which has PTO's on both sides.
These are pretty bulletproof and more common.

Hope this helps.

[Rolando14]

for that price, i just don't feel like i'm doing myself any favors... i found a trans for $200 last week but it turned out to be 4wd =(

Originally Posted by ArdWrknTrk

Welcome to the FTE forums Rolando!

I had a 1960's Dodge dump with a slant 6 that came from a cemetery.
It had never been registered and had similar mileage.
The front end was shot from all the low speed turning it did.

On topic: The ZF 5-speed is a desirable gearbox.
Here is the troubleshooting guide link: http://www.zf.com/na/content/en/impo...ing_Guide.html

There are also the exploded view: http://www.zf.com/na/content/media/i...2_Exploded.pdf
And data sheet: http://www.zf.com/na/content/media/i...2datasheet.pdf

Without looking inside I don't think anyone could tell you whether you're better off rebuilding or exchanging it.
If you can find a bellhousing (you don't say which engine displacement) you do have the option of a Borg Warner T-19 4 speed which has PTO's on both sides.
These are pretty bulletproof and more common.

Hope this helps.

Thanks ArdWrknTrk, that was all more than helpful. I am going to crack this trans open and take a peek. I'll take pictures when I do. Sorry for failing to mention it is a 351, v8. I am unsure if it is a windsor or cleveland, or if that's irrelvant.

I am going to check out these links right now. thanks!

[ArdWrknTrk]

Attn: FYI, per the troubleshooting guide.
"Check if there are any noise changes in a particular gear, i.e., 4th gear. In 4th gear the countershaft is not under load."

[alxsnmr]

The motor is a 351 windsor, the cleveland and its offshoots havent been produced in the US since the seventies. Australia saw it live longer though but that is a different topic. If you need another tranny to replace it, that shouldn't be that big a deal to find a 2wd 351 tranny, just a little more looking is all.

[Diesel_Brad]

i would spend a grand and have it rebuilt. Buying a used one is a crap shoot unless you know the person

[Rolando14]

that guide is really helpful. i would be lying to you guys if i said i knew a lot about these transmissions, i really don't understand much about them. luckily i have a buddy with free space and plenty of tools, he pulls tranny's out of fed ex trucks and various other heavy duty vehicles so i'll at least have some worthy input when he's around.

HONESTLY, my original thought was that the PTO was not disengaging properly, causing it to rub up against additional components of the trans. Either that or it wasn't properly installed.

without having a similar gear to compare with, would it be possible to ID a worn gear to the untrained eye? i'm probably gonna get going taking it apart within the next 2 days.

[ArdWrknTrk]

Originally Posted by Diesel_Brad

i would spend a grand and have it rebuilt. Buying a used one is a crap shoot unless you know the person

I've learned this lesson the hard way before...

[96 4D F150]

What are you doing with the truck?You may not need the overdrive the ZF has and could get away with an NP435 Granny low and PTO port.

For 200$ buy the 4WD ZF and resell it.Use that money to rebuild your ZF or buy another one.

I bought my ZF for 300$ and thought it was a smoking deal.I bought if off of Pirate4x4 from a local member so I felt alittle safer than a junkyard unit.Although I am buying a junkyard unit to put in a Jeep I have.

[Rolando14]

well it's a dump truck, so i have been dumping mulch, concrete, stone.... that sort of thing.

it is a work truck, so i am scrambling to find a replacement or get it opened up and see what the problem is.

insuring a vehicle that isn't making me money is a pain the ass =(

[96 4D F150]

Doesnt sound like overdrive is a must.Check out an NP435.Probably stronger than a ZF but no Overdrive

[ArdWrknTrk]

Stronger than the 542, but not the 547, which was used from '95

The T-19 has synchro 1st. IMO that's a + over the 435.

[Diesel_Brad]

Originally Posted by ArdWrknTrk

Stronger than the 542, but not the 547, which was used from '95

The T-19 has synchro 1st. IMO that's a + over the 435.

Yeah, but w a small block in a mason dump, i think i would want a creeper 1st of the 435 or T18

[Rolando14]

well apparently the 542 was a light duty trans for a heavy duty truck.


i suppose o/d isn't necessary...

the np435 hard to find? it's for older models i presume?