zf5 rebuild tools

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Apr 9, 2017 | 08:23 PM

wtrfwl havoc

Thread Starter

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Joined: Apr 2017

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zf5 rebuild tools

Anyone on here know what all special tools a guy needs to rebuild a zf5. getting ready to do a rebuild on one. I think I know most of the tools I need just wanted to see if anyone on here has the tools. or has rebuilt one that can tell me for sure what all I need. I have rebuilt many trannys but this is my first zf5. Just wanted to get my ducks in a row before I started

Apr 10, 2017 | 04:48 AM

EPNCSU2006

Lead Driver

Joined: Nov 2002

Posts: 9,557

Likes: 44

From: Concord, NC

I think several of the tools listed in the manual you can get away with not using, but I think the one I needed and didn't have was the clamshell bearing puller. The countershaft bearings are below the end surfaces of the gears so you can't get to them with a bearing splitter. I ended up cutting the races with a cutoff wheel. The other thing that was tricky was setting up the preload and pressing the bearing races into the front and rear cases. I've attached the service manual and a list of all the tools in the manual. It's been 7 years since I rebuilt the ZF in my truck, so I don't remember for sure which ones are definitely needed and which ones are just nice to have.

Attached Images

ZF S5-42_47__47M_Service_manual_compressed.pdf (4.26 MB, 3977 views)

Attached Files

ZF Ford Rotunda Tool Number.docx (10.7 KB, 779 views)

Apr 11, 2017 | 06:39 PM

timemachine455

Mountain Pass

Joined: Aug 2014

Posts: 158

Likes: 3

From: Venice FL.

there's a kit on e-bay.Buy now at $425 Seems pricey but it was at $500.
I tried to copy the link but can't get it to work.

Apr 27, 2017 | 12:20 PM

Brian Donoghue

Senior User

Joined: May 2012

Posts: 146

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You don't need any special tools. I was able to rebuild mine with a simple Husky tool kit the mechanics set with over 400 pieces. It wasn't that hard. I say take your time rebuilding it and take close notes. Redoing the synchro gears is the hardest part.

Jul 11, 2018 | 05:20 AM

Diesel_Brad

Fleet Owner

Joined: May 2009

Posts: 21,437

Likes: 76

From: Gilbert, PA

Quote:

Originally Posted by EPNCSU2006

Great links. Thanks

Jul 11, 2018 | 06:21 AM

HardScrabble

Temporarily Deactivated

Joined: Aug 2003

Posts: 1,859

Likes: 2

Looks like the start of a good thread. Here's a link to a thread I never finished but want to.

https://www.ford-trucks.com/forums/1...f5-issues.html

Here's a link to some articles:

ZF S5-42, S5-47 Transmission Specs & Ratios

Jul 11, 2018 | 12:14 PM

90paul250

Senior User

Joined: May 2018

Posts: 118

Likes: 0

From: Chicago

Here is a good thread, a few posts down it has a couple links to disassembly and reassembly.

ZF5 Disassembly Instructions - Diesel Forum - TheDieselStop.com