I'm in the process of rebuilding my zf5 when i found out the mainshat is toast, has a large chunck missing out of it, im woundering would the mainshaft from a small block zf5 be the same? I have a i6 300 4x4 with a zf5 in it and the one im rebuilding is 4x4 also.

Im not having much luck finding one so im really hoping they can be interchanged

 

These guys have all the parts listed for the ZF trannys. ZF542 Ford Truck 5 Speed Manual Transmissions Rebuild Kits - Drivetrain.com Number 32 for the main shaft. It looks like the internals are the same. Are you sure the 5spd behind the 300 is a ZF? Ford use the Mozda (sp) tranny behind the small block V8 and the 300 quite regularly.

 

If his I6 is in a F250 or F350, it will have a ZF5. Or if someone swaped in a ZF in his F150.

 

Ya, I was thinking in a 150. Around my part of the country you don't see many 250s and 350s with a I6 or a small block

 

Great link, but you read it wrong, 32 is 5th gear ON the mainshaft. If you look closer, each gear is listed twice, once on mainshaft, once on countershaft.

The correct number for the mainshaft is 28 Scroll to the bottom of the page for a picture of the breakdown. There are 3 different versions, one 2wd, and two 4x4 differing in length, but no key to tell you which is for what engines.

About a week ago someone was talking about rebuilding a ZF5 and had several questions. I pulled out the parts file and really dug into it. If you want to see the real break down, search for that thread and the links to the files I posted (sorry don't have time to find it myself right now). Interesting enough, it appears that ALL 2wd's use the same mainshaft and rear housing. ALL 4x4 diesel and big block gas (460) use the short mainshaft and short rear housing. ALL 4x4 small block gas (listed as 4.9/5.8 liter) use the longer mainshaft and longer rear housing. If the ZF5 was behind the 300 I6, (~4.9L like the 302), it would NOT fit your transmission. Neither would one from a 302 or 351 for that matter. One from a 460 would.

Why those are longer, I have no clue.. Can you post a picture of your busted mainshaft, I'm curious to see it, and where/how its broken. These are pretty tough transmissions, maybe its not as bad as you think (maybe it is though). When I tore mine down to swap the cracked case, I found that one of the reverse gears had a tooth broken off. The tooth was at the bottom of the case, and seemed to have been there for a while. No indication that it was an issue or that it was causing any abnormal wear, so these are pretty tough tranny's.

 

Tecgod, you are right, I didn't read it right. My bad, thanks for the correction.

 

Do you have this disassembly manual that is hard to find???

Ultimate factory manual on how to take it apart and whatnot....

http://www.zf.com/na/content/media/u...ce_manual_.pdf

 

I have that manual now, a bit late but i do have it, the part was actualy broken by me, i typoed in my first post, i was pressing off the 5th and reverse synco when it broke, im not sure what broke it, me pressing on the wrong part by acident (i could of swore it wasnt on the part that broke) or when it let go and fell it met its end there

 

Aww heck, that's just a scratch. Personally, I would either run it as is, or, in my case, I could build that back up with weld and have it reground to size....but not everyone has that option. Welding a hardened shaft is not something one can do in just any garage or backyard shop either.

 

Been quite a while since I was in a ZF5 and my memory isn't what it used to be. What exactly rides on that flange, a thrust bearing, thrust washer or the gear? If it is a washer or the gear, I would just grind the edges smooth and run it as is.

 

I'd agree with the above. As long as its not bent out of wack at the break, clean it up and reuse it.

 

Just an update, I found another mainshaft so I'm back in business agin, thanks for all your help everyone