Has anyone ever rebuilt a s542 or s547? I read that some of the bearings have to be replaced under pressure. Is this true? Should I try to install new bearings and seals in my junkyard ZF, or just use it as is?

 

I never rebuilt one but Ford offers a rebuild tool kit with special tools. There is one for sale on ebay and at the bottom of the posting it has drawings and descriptions of the tools included in the kit:

http://cgi.ebay.com/ebaymotors/ws/eB...4035&rd=1&rd=1

 

I was just going to post the same question, I have an S5-42 that I am putting in my Cummins conversion but I want to rebuild it. I would also be interested in hearing from someone who has done it. I can't seem to find any rebuild manuals for it either.

 

Ford's shop manual tells how to rebuild it. You can get one on-line. This thread talks about it: https://www.ford-trucks.com/forums/5...hlight=fordcds

 

Wrench52, I just ordered my s542 manual off of ebay for 12.99. I didn't find it under ZF, it was listed as s542.

 

WOW, I've been screwing around with trying to download one those Ford CD's for hours with no luck. I'll just buy one of those off Ebay. I searched Ebay under ZF and couldn't find anything for the S542. Thanks!

 

Bummer, no more S5-42 manuals available at that store.

 

Keep watching. I got mine last week, and right after, they posted another one for $9.99. let me know if you find any info on the rebuild difficulty.

 

I was finally able to get into one of those Ford CD's although the year had only the ZF6. I looked at the rebuild procedure, doesn't look all that bad, a press and some sockets, pipe nipples, pullers, etc will have to be used to remove, install the bearings on the main and counter shaft and a plate will have to be fab'd to hold the shafts/gears while they are being dissassembled. The bearings are heated to 300 deg max to install on to the shafts, should be able to use a hot plate and some oil to heat them along with a thermometer. There are shims that are used behind the bearing race in the front case to set the preload on the bearings. The cases are temporarily assembled with the assembled shafts and without the shims, then the end float of each shaft is measured with a dial indicator then the thickness of the shim to use is determined with the procedure given. Then the races are popped out, shims installed behind race and then the unit is assembled. It gives a part # for a gasket maker sealer and specifically says do not use silicone sealer so i think I'll ask the dealer what the stuff is, maybe just something like original permatex #2. There's lot of parts so the hardest part will be just keeping track of where everything goes but the pictures are very good. I'll be tackling mine in a few weeks once I get the Cummins 4B together.

 

I just read that you need the tag numbers on the side of the trans to I.D. the trans in ? since there are numerous gear ratios and that the zf 542 and the newer zf 5?? look almost the same. You'll probably be asked for the tag #'s when ordering parts.
Good luck