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I just bought an 87 F-250 Diesel with a ZF tranny. It has a lot of miles on it, and acts like it needs synchros. Are these seperate brass synch's like the old muncies and Chevy trans or are these like the NP 435 and part of the gears?
If it needs syncros, you might as well just live with it or put a new re-man ZF tranny in it. The parts are rediculously expensive for the ZF's, and its cheaper to buy a re-man than it is to rebuild it. My '88 F-250 has the same tranny in it, and all the syncros from 1st through 3rd are gone. After awhile I've gotten used to matching the rpms before shifting, or double clutching if need be. I'm planning on running it until it blows up or I cant stand it any longer.
A re-man ZF will run about $1,500 to $2,000. Chances are when you tear into yours you'll find that between syncros, bearings, seals, any gears that are needed, plus labor, your looking at that much or more, plus a big hassle. Sorry I cant answer your exact question, but I personally have never had one apart. I do know that they use a cone type syncro, but thats about it. Hope some of this info helps you out, I'm going through the same thing right now.