ZF5 Shifting Issues

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Aug 9, 2023 | 08:47 AM

BRuffner

Thread Starter

4wd Low

Joined: Jul 2023

Posts: 10

Likes: 1

ZF5 Shifting Issues

1997 F-350, Crew Cab, DRW, 7.3 w/ ZF5

Hello All,

I've gotten some seat time behind the wheel of my truck (finally) and I've noticed some issues.

Now I've driven several manual trucks owned by friends/family in the past (NV4500, ZF5/6). My truck is a chore to shift compared to them. I changed the shifter bushings, which helped immensely with the shifter side of things, but I believe I might have a bent shift fork (you gotta ask nicely to go in reverse or it grinds).

I can deal with a sloppy shifter, but the clutch is ridiculous. The other 3 ZF trucks I have driven are cakewalks compared to mine. Slipping it is the biggest chore.

Are there any aftermarket improvements I can make to the clutch assembly to help with the stiffness? I am not the only one driving this truck, so an improvement over what it is currently is worth it, even if it means dropping the transmission.

Thanks in advance!

Sep 6, 2023 | 12:16 AM

gearfather

Cross-Country

Joined: Jun 2010

Posts: 53

Likes: 4

From: st.paul. mn

before retiring (again) my company remaned 4200-4400 manuals a year for ford gm chrysler and several imports. that being said, big deal. clutch...clutch....how does it shift with the engine off and sitting still ?

Sep 6, 2023 | 06:00 AM

BRuffner

Thread Starter

4wd Low

Joined: Jul 2023

Posts: 10

Likes: 1

Quote:

Originally Posted by gearfather

That's a very good point I hadn't thought to check. The transmission shifts decent sitting still through 1-5 (Forward Gears). While there is about 3-4 inches of play to the left and right while in gear, I can usually hit what I'm asking for while driving (occasionally I have issues crossing over from 2 to 3). When shifting into reverse, there is almost a...ledge? Pulling back towards one direction (I believe left) while going into reverse, it will fully engage. Pushing the shifter as far right as possible, and then pulling into reverse, there is a point where you feel resistance. If you let out at this point, no power gets transmitted to the back wheels, and you hear gears inside the transmission (I believe the idler or maybe a syncro) starting to grind.

As for the clutch, I have a new bushing on the way and I've done the easiest job of lubricating the joints in the pedal and checking what linkage I could see. Lubricating did not help much. I believe my stiffness issue could be related to slave cylinder/throwout bearing but I'm not sure yet on how to diagnose those (I've got some reading to do).