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ZF speed rebuilt

 
  #1  
Old 11-07-2010, 01:11 AM
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ZF speed rebuilt

well i took the plunge and rebuilt the tranny myself. i never found a shop around here i thought was reasonable nor that i trusted. which in the end i am glad as i got to do a few other things like pressure wash the under side of the truck, replace all my rear driveshaft ujoints, and i found the clutch issue. Peter from Southbend was very nice and helpful, and the only question he asked was where to ship the new clutch. we will see how it all turns out in the long run.

a big thanks to Ian who i had "on call" just in case, thanks man! the biggest help in all of this was the rebuild manual on TDS. All in all it wasnt hard, gotta have a couple of special tools but nothing you wouldnt use for any other project. bought the overhaul kit from Transtar. if i were to do it again i would buy the deluxe kit, what i bought didnt have the small parts kit that i needed.

Rebuild Kit = $300
3rd gear = $200
Small parts kit = $100
Red Line ATF = $40/gal x2
LocTite 518 = $15/tube x2
throwout bearing = $50
pilot bushing = $40
Flywheel resurface = $70

I have right at $850 in it right now which is less than half of what i was quoted around here. 3rd gear was mostly my fault and is not typical of the rebuild. the throwout bearing feels iffy so i just decided to buy a new one and be safe, same with the pilot bushing. these are not necessarily needed on every truck. a typical rebuild should come out to about $500.

anywho here are some pics of the project.

First the teardown:












rebuild kit with synchro kit:
 
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Old 11-07-2010, 01:22 AM
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and here are some build up pics:





comparison of synchros, this one was the best lookin one and its reverse! lol


this is why i had to buy a new 3rd gear. stupid me tried to separate the taper cone which in the end did not need to be done!


mainshaft all buttoned up:


extension housing put back together. this is actually very difficult by yourself and without the holder assembly ford recommends! took me about 7 tries to get everything lined up!


main housing installed


and this is how she sits right now. after installing all the small parts i put some fluid in and ran it through the gears. this let me test all the gears and coat the gears with some fluid. i am leaving it overnight to see if it starts to leak. i am not reinstalling it if it does leak.


i have a good deal more pics, if you would like to see them check out my picasa gallery down in my signature. or you can check out this thread:
http://www.bustedknucklefilms.com/fo...ission-Rebuild

-cutts-
 
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Old 11-07-2010, 08:25 AM
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Very nice! What did you need for special tools? Saving all that labor cost would certainly pay for a lot. Well done.
 
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Old 11-07-2010, 09:08 AM
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Nice Job!!
 
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Old 11-07-2010, 09:32 AM
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awesome pics! our diesel mechanic was going to teach me how to rebuild this bad boy over the winter, it actuallydoesnt look that bad at all to be honest with you. ive tackled plenty of small motor trannys like bikes and atvs and its all pretty much the same thing. i think ill be doing this myself soon too.

What exactly did your rebuild kit consist of? syncros? mine are JUNK
 
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Old 11-07-2010, 09:48 AM
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just looked at your other forum post from BKF and im all giddy now to start this project! im a few months away thoe LOL
 
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Old 11-07-2010, 09:56 AM
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thanks guys, it has been a fun and educational experience for sure! i am ready to get the ole girl back on the road, pushing three weeks now.

Originally Posted by MagKarl View Post
Very nice! What did you need for special tools? Saving all that labor cost would certainly pay for a lot. Well done.
the biggest special tool i actually ended up buying was a three jaw puller that was longer than 6". i ordered an OTC 10 way kit and i feel it already paid for itself. i also had to use the puller with slide hammer feature to remove the 3 shifter detent plugs.

Originally Posted by rideracelivemx7 View Post
awesome pics! our diesel mechanic was going to teach me how to rebuild this bad boy over the winter, it actuallydoesnt look that bad at all to be honest with you. ive tackled plenty of small motor trannys like bikes and atvs and its all pretty much the same thing. i think ill be doing this myself soon too.

What exactly did your rebuild kit consist of? syncros? mine are JUNK
ya i have done several old school trannies and transfer cases for offroad rigs so i am not new to gears. this tranny is just a lot more tedious than those.
comes with gaskets/seals, some bearings, and synchros. here is a pic of the kit:


-cutts-
 
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Old 11-07-2010, 10:02 AM
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Nice job!!! One thing I do enjoy about working on these trannies compared to an older T-19 or NP435 is the whole assembly just slides out makes it much faster than trying to get my big hands inside a tight cast iron case. Thanks for posting the photos!!
 
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Old 11-07-2010, 10:03 AM
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this is the puller i used and here it is in action:
http://www.amazon.com/OTC-7948-Silve.../dp/B0002SRI5U



what i had to do here was drill a pilot hole in the plugs and then screw the included metal screw hat came with the kit. then the slide hammer threads on and just start slide-hammering until it comes out.
 
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Old 11-07-2010, 10:16 AM
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Could you put together a tool list for us?

I know a few on here want to do a rebuild.
I know travis is working on his right now as well.


Did you replace the throw out bearing sleeve as well?
I know its pressed in on the older trans.
 
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Old 11-07-2010, 10:18 AM
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oh hey, nice tool box, looks like my nice Kobalt. =)

Did you have to press any gears besides the 3rd gear you broke to get the syncro's off or anything?
 
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Old 11-07-2010, 11:22 AM
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I will have to do that to mine this winter. Ha ha it has needed it for the last two winters, but it just seems to keep going! Nobody likes to borrow my truck because nobody can shift the dang thing.
 
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Old 11-07-2010, 01:09 PM
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Looks great! How was it to shift through the gears the first time?
 
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Old 11-07-2010, 02:14 PM
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Where did you get the rebuild kit from?
 
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Old 11-07-2010, 06:29 PM
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Originally Posted by Talyn View Post
Could you put together a tool list for us?

I know a few on here want to do a rebuild.
I know travis is working on his right now as well.


Did you replace the throw out bearing sleeve as well?
I know its pressed in on the older trans.
no i did not replace the sleeve. it was in good shape.

sure i will list the tools i used while it is fresh on my mind. please note there is no organization to the following list and you could do the project without some.
basic hand tools (scewdrivers, pliers, etc)
metric and SAE shallow sockets
metric and SAE allen keys
brass hammer/punch
metric and SAE tap/die set (i always clean threads)
parts washer
OTC slide hammer set
bench vice with soft grips (wood in my case)
engine stand
snap ring pliers
toaster oven (to heat the bearings and synchro hubs, NECESSARY)
small paint brush and clean container (i brushed ATF oil on the bearings after installation)

i think that was pretty much it, i will post other tools if i think of them

-cutts-
 

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