ZF 5 wont fully shift into reverse
Thread Starter
|
Junior User
Joined: Jan 2009
Posts: 80
Likes: 0
ZF 5 wont fully shift into reverse
As the title reads my trans is having some issues. It will shift into all other gears just fine but when I try reverse it feels like it just barely engages the gears. I can hold the shifter forcefully in gear and the truck will move but otherwise it just pops out any ideas what to check?
Senior User
Joined: Sep 2013
Posts: 276
Likes: 0
From: Orange County NY
How does the shifter feel?
If it's not sloppy, then your reverse synchro is finished.
Mine is almost there. I sometimes click it into reverse 2-3 times before I'm sure it won't pop out. I can tell when it's not all the way in and it does stay in 39 times out of 40, probably.
If it's not sloppy, then your reverse synchro is finished.
Mine is almost there. I sometimes click it into reverse 2-3 times before I'm sure it won't pop out. I can tell when it's not all the way in and it does stay in 39 times out of 40, probably.
Thread Starter
|
Junior User
Joined: Jan 2009
Posts: 80
Likes: 0
Well I was hoping it was something simple. I just had the case separated because the bell housing was busted when I bought it. I guess I'll be pulling it again. How hard is it to change out the syncros? I've rebuilt auto transmissions before but never a manual.
Senior User
Joined: Sep 2013
Posts: 276
Likes: 0
From: Orange County NY
I used to fix VW trannies quite a bit. I would think, these are easier.
When you put yours back together, did you make sure your end play was right?
If the input, output or counter shafts have too much slop, the shifter fork will push the whole shaft and the sliding gears might not click all the way in.
Post Fiend
Joined: Nov 2005
Posts: 7,437
Likes: 4
From: Charles Town, W bygod Va
Thread Starter
|
Junior User
Joined: Jan 2009
Posts: 80
Likes: 0
I didn't check the end play. I honestly didn't know how and was hoping the trans was ok since all I did was swap cases. I didn't disturb any gears at all so this must have been an issue already.
Thanks for the rebuild link
Thanks for the rebuild link
Lead Driver
Joined: Apr 2008
Posts: 6,944
Likes: 13
Trending Topics
Senior User
Joined: Jan 2013
Posts: 327
Likes: 0
From: West Aus
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
10 Things Every Truck Owner NEEDS (2026 Edition)
Michael S. Palmer
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Verdad Gallardo
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer
Joe Kucinski
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make
Brett Foote
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!
Michael S. Palmer
Ford's 2001 Explorer Sportsman Concept Looks For a New Home
Verdad Gallardo
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
Thread Starter
|
Junior User
Joined: Jan 2009
Posts: 80
Likes: 0
Well a friend did some research for me since I work full time and go to school. He found a company that sells a kit to quote "fix the common reverse issue with the ZF5". It includes syncros for reverse, 5th gear syncros, and some other parts. I can't remember all he told me. I'm gonna look it up when I get to work today. I guess the only way to be sure is to tear it down. Ugh
Senior User
Joined: Sep 2013
Posts: 276
Likes: 0
From: Orange County NY
Well a friend did some research for me since I work full time and go to school. He found a company that sells a kit to quote "fix the common reverse issue with the ZF5". It includes syncros for reverse, 5th gear syncros, and some other parts. I can't remember all he told me. I'm gonna look it up when I get to work today. I guess the only way to be sure is to tear it down. Ugh
This^
They're not the same synchro exactly. They're on the same sliding gear tho.
Edit: I'd rather not even have a syncro for reverse. I guess, with no clutch brake, a tranny this big would grind like a SOB.
Thread Starter
|
Junior User
Joined: Jan 2009
Posts: 80
Likes: 0
After a little searching I've found a few people have a bushing go bad in the pedal that won't let you get enough pressure on the clutch to fully disengage it. This drags the clutch just slightly and will not let reverse engage. So looks like I'm crawling under the dash tonight. I'll report back if I fix it. Seems like this post has attracted a few fellow gear grinders that could benefit from a fix.
Senior User
Joined: Sep 2013
Posts: 276
Likes: 0
From: Orange County NY
My clutch grabs a little low (new last month).
It's enough to stop the input shaft though. I can tell by the way the shifter feels and the feel and (audible to only a dog..or me) sounds coming through the floor.
If I don’t put the pedal right on the floor, though, reverse will almost definitely pop out.
I can feel when it has clicked in. If it doesn't "clack!" (the detent clicks every time but the sliding gear doesn't always engage all the way. I can hear/feel the difference), then it pops out.
That's right though. If your clutch isn't disengaging completely, or if the pilot bearing is turning the input shaft, the pispoor reverse arrangement will give you fits. The synchro and slider will click in but the gear won't. After they wear, there is enough slop that the gear can half engage so that the synchro isn't locked to the gear.
The fix-it 5th/reverse slider/synchros would correct this, I'm sure.
It's enough to stop the input shaft though. I can tell by the way the shifter feels and the feel and (audible to only a dog..or me) sounds coming through the floor.
If I don’t put the pedal right on the floor, though, reverse will almost definitely pop out.
I can feel when it has clicked in. If it doesn't "clack!" (the detent clicks every time but the sliding gear doesn't always engage all the way. I can hear/feel the difference), then it pops out.
That's right though. If your clutch isn't disengaging completely, or if the pilot bearing is turning the input shaft, the pispoor reverse arrangement will give you fits. The synchro and slider will click in but the gear won't. After they wear, there is enough slop that the gear can half engage so that the synchro isn't locked to the gear.
The fix-it 5th/reverse slider/synchros would correct this, I'm sure.
Logistics Pro
Joined: Apr 2005
Posts: 4,221
Likes: 17
Also check the firewall around the clutch master cylinder, the area is prone to cracking and flexing causing clutch disengagement issues.
Fire Wall clutch plate 101
Related
Technical Service Bulletin
Terrapin Manufacturing <--- Guy that makes the firewall reinforcing plate. 1983 to 1991 F-Series
Fire Wall clutch plate 101
Related
Technical Service Bulletin
Terrapin Manufacturing <--- Guy that makes the firewall reinforcing plate. 1983 to 1991 F-Series