It was info on a S5-47 from a '96 service manual on thedieselstop.com. What year truck manual do you have? I know a lot changed between '89 and '96. I also have a '92 service manual on CD from someone on here.

 

I love the heck out of my ZF. It sits behind my 351W swap that I already had done by then, but it cruises beautifully. I am running 35" tires (315/75 R16) and cruising speed at 70mph is 2000RPM. Even still by running the stock 3.55 gears. And yeah, the low low first and reverse gears are great for towing! Hope you get yours back up soon!

Also one other thing to check would be to check the stamping on your trans and make sure that it is a S5-47. I don't know if its a difference in the years, but the stamping on mine makes it an S5-42, which could change your torque measurements.

 

Your '92 Shop Manual will be the same as what I've got.
Mine's a '91 and I only copied the exploded view and its
list, re-assembly and adjustment sections.

If someone wants it, just say so and I'll -email- ya the URL.
I don't want to post it on FTE. :( ...for lots of reasons. ;)

Cool post, Night. :)
http://www.panix.com/~alvinj/file12/BroncoZFtag.jpg

What I'd like to have is a -parts CD- for '91 trucks! :)
Anybody got any leads on one? :)
I've got the one that goes up to '89.

Alvin in AZ

 

I meant that the online manual I found on thedieselstop.com was for a -47. Mine is a -42 for sure, manufactured 6/3/91. The tag is almost the same as what Alvin posted, but mine is a -051 part number with an 8 tooth speedo gear. I'll be sure to take as many pictures as I can throughout the whole process.

 

Cool! :)

That's what I need is part numbers, pictures, anything and everything! ;)
...just to get me a new 8 tooth speedometer drive-gear. :)

Kyle O. is having trouble with it, I'll email 'im the new -051 information. :)

Speedometer ratios I fiNgured out:
7t + 18t -with- 29" + 3.55
8t + 19t -with- 31.5" + 3.55

Question is... did I get my numbers right? :/
Eppy, how far off is your speedometer with your 29" tires and 3.55 axle?

I haven't driven my '91 Bronco yet, see? :/
Got two more things to do before -just- getting it off the blocks!. LOL :)

Alvin in AZ

 

The -051 ZF part number is listed in their application progression chart for trucks having a 3.55 rear end ratio, with the -050 being used on trucks with the 4.10 rear end ratio. I thought that would mean plug and play with no recalibration on the speedometer necessary, but I didn't think about the bigger tire size of the F250.

My F150 came with an 18t (yellow) driven gear; the ZF also had an 18t driven gear, so I thought I would be good to go, but without knowing that the truck originally used a 7t drive gear, the speedometer was off when I first started driving with the ZF. I ran the two drive gears through a speedometer gear calculator online and determined that I needed a 21t driven gear for approximately the same gear ratio as before: 18/7=2.571 and 21/8=2.625. The 18/8 combination was overdriving the speedometer by about 15%.

If I can find the right part, I'm thinking of swapping out the 8t for a 7t drive gear while I have the ZF torn apart. The 18t driven gear seems to have much more substantial teeth than the 21t gear.

 

I don't know how you feel about the aftermarket, but to solve this whole problem on my 87, I got an AutoMeter Electronic sending unit that you slide the driven gear on and wire to the electronic speedometer, then you just program the speedometer. Its quick and easy, and any time I change tire size, gear ratios, etc. it takes a mile's worth of driving and 5 minutes to re-calibrate the system. Also, the speedometer has an output that you just wire back into the input for CC and you get to keep that too! Anyway, its a thought.....

Here were the two that I got
Programmable sending unit
Auto Meter 5292 - Auto Meter Programmable Electronic Speedometer Senders - Overview - SummitRacing.com
Electronic speedometer
Auto Meter 5887 - Auto Meter Phantom Series Speedometers - Overview - SummitRacing.com


Here's a pic of it, its a lil old as the sirius reciever is now right above my CB Mic on the diamond plate switchboard


Well that one kinda sucks, here's a close before and after.....I hadn't blacked out the back plate yet in the after pic but I have since then
Before


After

 

That's pretty cool. I don't think I'll go to an aftermarket speedo, at least not anytime soon. I did look into replacing all the OEM gauges with aftermarket gauges a while back, but the cost was just not worth it for me. The new driven gear actually puts the speedometer closer to the actual (GPS indicated) speed than the original.

 

I have the geartrain out of the case, sitting on the workbench, ready to pull apart. The FSM shows several specialty pullers to get the mainshaft apart, but I know folks here have successfully rebuilt these ZFs without those tools. For those of you who have rebuilt one of these without the Ford tool kit, how did you pull the bearings and gears? Are there any good places to get ZF parts other than the dealer? I think someone posted a link a while back to a company selling rebuild kits. I would like to get the mainshaft apart before ordering parts so I don't forget to order something I need, but I'm eager to get this show on the road and the truck back in service.

Most everything looks good from what I can tell, although there was a good amount of buildup on the magnet, and the gears showed some wear on the flanks of the teeth. How much wear is normal? The reverse gear on the mainshaft doesn't spin as free as the others, so that may be causing some of the noise I was hearing. The tapered bearings on both ends of the mainshaft and countershaft look to be in really good shape.

I very much appreciate everyone who has chimed in to help with this project. Hopefully I can get this project off the list in the next few weeks, although I may have to take a break to knock out my tax returns

 

To take it apart I was told...
"slam it down on the concrete! :)"
...but I ain't got no concrete. :/
Do have a big hunk of iron from the scarp yard tho... ;)
http://www.panix.com/~alvinj/file12/zf3.jpg
Like he said...
"wrap it up in a rag to contain the parts that are gonna fly :)" LOL :)

Also... as I found out, it'll ruin a special retainer (snap) ring too.
No sweat, buy a regular one and grind it down to work, 2+1/4" inside
fits and works good, got mine from a well stocked Ace Hardware...
http://www.panix.com/~alvinj/file12/zfSR.jpg
The gold one is the one I bought and modified.
The odd looking one is the original and you can see it's done-for. LOL :)
The "little" one is off a dirt-bike sprocket and serves as a reference. :)

Here it is going back together...
http://www.panix.com/~alvinj/file12/zf7.jpg
...was waiting on a friend to bring me the snap ring out from town and
took that picture. :)

Two used Ford9inch axle retainer rings, the ZF's yoke and an idler gear
shaft from a washing machine and the bearing cone hammered home,
no sweat. :)
{edit}
http://www.panix.com/~alvinj/file12/zf4.jpg
{how you like my 8 pound single jack? :}

The one part that spooked me was the part "slammed off" in the first
picture... http://www.panix.com/~alvinj/file12/zf3.jpg ...that's a long
sucker to get hammered on "half way" and have stop moving on you! :/

So I heated that part up 'til it smoked (oil cooking off) and put the
mainshaft in the freezer (-5*F) for a couple hours and that baby rang
when it fell on. :) The part is an inner-needle-bearing-race that doubles
as a mainshaft "diameter increaser" too. You'll see the need for it. :)
Then you'll think... "I see what nutty-boy was going on about now :)"

http://www.panix.com/~alvinj/file12/zf2.jpg
That's #2 and just before picture #3 and the only ones-of taking it apart.
Those are two old rusty leaf springs held together with a 5/16" bolt.
The thick brass washers are used Ford-FE engine clutch pilot bushings.
The pretty;)pink thing is a homemade ZF stand made from a 5 lug air
cooled VW wheel. Handy as anything for finishing-cleaning it but, not
for-sure needed.

----------------------------

In the mean time, I've gotten to drive my '91 Bronco with the ZF in it! :)
Towed it home and set it up on blocks 11 months ago. LOL :)
First time I drove it really. :)

The 3rd gear synchro hub's pointy teeth are worn and will pop out of
gear on me if I don't shift it just "right". No big deal. It's clean now! :)
Cleaning that sucker was the hardest part of the job, IMO. Taking it all
apart and messing with it was the fun part! :) YMMV?

Bought new bearings but didn't install them and yes the old ones are fine
(just a little bit noisy) with 188k "company truck miles" on on 'em. So now
that the "core" has been proven good, I'll take it apart again and rebuild
it -all the way right- this time and enjoy doing it too. LOL :)

BTW, the '91 Bronco's got a nick-name now... "rattle trap :)".
It won't rattle when I get done with it! Not nuthin, not ever.
Believe it? :)

Nutty-Boy in AZ is a tinkering fool

 

Hey, im about to be rebuilding a -42 i got from a junk yard, mainly to swap mainshaft and tail housing for a 4x4 so i can use it in my truck. Any pictures and info you can give me would be great. Do you have a manual your using? How dificult was/is it to do?

I'v pulled apart huge transmissions off of tractors and dozers and other equipment, rebuilt engines and axles but for some reason the zf is more intimidating.

Thanks

 

LOL :)
The ZF sure as heck -is- intimidating. :)
...because Ford wants it to be! :(
That's all. :/

I have no where near the experience you do and did it. :)
Used my '91 Ford Truck Shop Manual and found a mistake.
They got the wrong picture in "sub-assemblies" step 13. :)
Threw me for about a half hour, but I'd taken pictures.
The pictures were only used to assure me I wasn't loosing it. LOL :)
Ummmm... think it's just a coincidence it's "step 13"? ;)

More straight forward than replacing a ring and pinion, IMO.

Here's my favorite ZF picture... :)
http://www.panix.com/~alvinj/file12/zf1.jpg
All the fun's over... :(
http://www.panix.com/~alvinj/file12/zfF.jpg

Alvin in AZ

 

It looks like it went together nicely for you. Maybe you should do mine for me

Anyways, does the manual go through the tear down and rebuild pretty well? All i have is a haynes, but i think a real shop manual would be a good investment at this point. And pictures are defiantly a must every step of the way.

 

This i a manual i found on ebay. It looks like it covers everything. Is it simular to what your using?

1992 FORD TRUCK OWNERS/REPAIR/SERVICE/SHOP MANUAL : eBay Motors (item 200450930767 end time Mar-23-10 10:09:50 PDT)

 

The exact same stuff I've got, only mine's 1991. :)
Anybody that's got a '92 and wants to keep it and work on it
themselves needs to get the real Ford books like those and
quit fartin' around with that dumbed-down half-assed Haynes
and Chilton's crap. ...IMhumbleO of course. ;)

-----------------------

Here's a list of the books after the eBay-ad is dead and gone...
Electrical & Vacuum Troubleshooting Manual
Light Truck Shop Manual volume 1 <-- ZF is in this one
Light Truck Shop Manual volume 2 <-- engine stuff
Powertrain Control/Emissions Diagnosis Shop Manual
The '91 version was called...
Engine/Emissions-Diagnosis Shop Manual

Are the wiring diagrams in that set he's got there?
Ask 'im for me. :)
Are they in the PC/ED binder?

Not needed really (IMO) but the Specifications books volume 1
is for the little Rangers and volume 2 for U and E+F-series.
If you want to get just one of them. ;) Ford messed up on the
'91 version and left Bronco (U) off the front cover. :/ Spooked
me for a minute there. LOL :)

Alvin in AZ
ps- I have the useful parts of the ZF re-assembly scanned at 300%
and loaded on my website, but I don't want to put its URL on FTE. :/
pps- If you want it, meet me on another website forum.