Hello all! It's been ages since I've been on here. Life being busy and all. Lots of changes around my household, but the ol' '96 Crew cab is still in the stable.
Got thinking about this group as I've had the truck in my shop for the last couple weeks doing a rebuild on the ZF5. Had it complete, but found issues. Issues with the rebuilder, and his abilities to rebuild. Isn't that just the way. Anyhoo, Now that I've said hello, I'll soon get back on here with updates as I think I've figured out my assembly error and will give it another go tomorrow.
Pics to follow for those that may be interested.

 

Set on the tail end then take the housing off.


A good look at the shift rails


Full assembly on the bench with tail section removed. Ratchet straps hold the assembly together so you can remove the tail section



Main shaft with input shart removed. Oil slinger ring was cooked and crumbled to pieces. No wonder she ran hot


Couter shaft. Worm section had some wear, but still good enough for the amount of miles i put on it.


Synchro ring teeth detail. 3 teeth cut down in 3 locations on each ring for the detent springs and plates. VERY IMPORTANT THAT THESE ARE LINED UP CORRECTLY!


Looking down through the shifter tube.

 

Hello Dave, it`s been a long time since we`ve heard from you, great to hear you`re alive and well!
Good to hear you still have your 96 Super Crew. Are you still cooking your own diesel fuel?
A few yrs ago I bought my friend`s 01 F250 Lariat Super Crew after he passed away suddenly. The transmission was shaky when he drove it last so right after I bought it I had a rebuilt AOD installed.

 

Hey Morris. Since moving to town I haven't made any homebrew. Hope to again some day.
Nice looking rig you got there.

 

Thanks Dave, it`s in nice shape. 435,000 kms on the clock with a tiny bit of rust just starting above the rear wheels.