manual hard to down shift into 2nd
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Junior User
Joined: Jun 2008
Posts: 52
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From: zavesville, ohio
manual hard to down shift into 2nd
i am new to this 5 speed so thought i would ask some of you that have them. i have a zfs542 5 speed that upshifts fine but seems to want to grind going into 2 when downshifting. will go into 2nd without grinding if i slow to about 10 mph first. is this normal behavior for this thing or does it have problems? thanks for your input.
Elder User
Joined: Feb 2008
Posts: 867
Likes: 3
From: North Bend
Yup, just blip the throttle and it should match up. It's worn syncro's, I have them into 2nd, 3rd, and 4th. Apparently I had a crappy previous owner.
At least yours only chatters when downshifting! Hahaha mine is 3 of 5 gears every which way...
At least yours only chatters when downshifting! Hahaha mine is 3 of 5 gears every which way...
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Junior User
Joined: Jun 2008
Posts: 52
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From: zavesville, ohio
yes,i can match the rpms and get it in gear, but does any one have one that will go in without doing that? this trans is out of the truck right now and i am debating as to rebuild or not. prefer the "not" option,but i dont want to do it later either. ive got to get this back on the road asap. i may split the case and measure the syncro's gap.
Mountain Pass
Joined: Sep 2010
Posts: 136
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My ZF5 shifts fine both ways without grinding pretty smooth with just the clutch.
If mine was like that and out of the truck I would have it fixed but if you can't wait, then you can't wait.
If mine was like that and out of the truck I would have it fixed but if you can't wait, then you can't wait.
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Junior User
Joined: Jun 2008
Posts: 52
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From: zavesville, ohio
split the case and got it apart, not to bad to this point. the problem and time consuming part would be disassembling the main shaft and setting it back up for preload with new bearings and ordering parts. however i was able to measure all the syncros gaps except 1st (low). the manual says.024 is the minimum. they all are .030 to.032. should be good i guess.
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Elder User
Joined: Feb 2008
Posts: 867
Likes: 3
From: North Bend
There's another thread around that goes into depth about the different fluids that the ZF says are approved for this transmission, as well as what people feel works or doesn't work...
Everyone recommends ATF for these, but most people find that it leads to chatter. Full Synthetic ATF works better, many report.
One interesting thing to note is that ZF does approve gear oil, but people tend to burn up the synchros doing that(or at least that's what was reported online)
After a lot of research I've found something called MTL, or manual transmission lubricant. It's unique in that it has friction modifiers specifically built for the synchros inside a transmission. Redline has some(which I am using), penzoil makes some as well, called Synchromesh, and I'm sure there are others. Autozone carries synchromesh, but usually not a lot at one time.
So if you aren't going to rebuild it, at least put full syn ATF or since that's expensive you may as well spend some more on MTL and then you'll at least know you did the best you could.
Hope it works better for you!
Everyone recommends ATF for these, but most people find that it leads to chatter. Full Synthetic ATF works better, many report.
One interesting thing to note is that ZF does approve gear oil, but people tend to burn up the synchros doing that(or at least that's what was reported online)
After a lot of research I've found something called MTL, or manual transmission lubricant. It's unique in that it has friction modifiers specifically built for the synchros inside a transmission. Redline has some(which I am using), penzoil makes some as well, called Synchromesh, and I'm sure there are others. Autozone carries synchromesh, but usually not a lot at one time.
So if you aren't going to rebuild it, at least put full syn ATF or since that's expensive you may as well spend some more on MTL and then you'll at least know you did the best you could.
Hope it works better for you!
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