Just picked up a used ZF S5-42 tranny from a '89 F250 to swap into my '86 F250 ($180 for tranny, transfercase, and crossmember and he even pulled it all for me). The truck was driven untill about 3 months ago when the owner nailed an elk and parked it (front end is toast). The truck has 170,000 miles on it, almost all highway (160 mile round trip commute to work each day for him) and he said it had no problems with grinding, whinning or poping out of gear. Playing with the transmission in the garage, it didn't seem to have a lot of slop while shifting, but I don't know how that correlates to how it will drive. I will be pulling the PTO covers to have a look inside to look for burned gears/bearings or chunks, but am wondering if any of you fellow forum goers knew of some problem areas I should look at to check for wear/abuse. It will be getting a new clutch setup and throw-out bearing, and new fluid before it goes in my truck, and I can have it rebuilt if I have to, but would prefer to save a little money if its feasible. Speaking of fluid, what would you guys recomend? I have heard the ATF recomemded by Ford isn't the best at protecting and lubricating the bearing and moving parts.....any suggestions on what to fill it with?

Thanks for any info or suggestions.

 

It sounds like you've covered most of the basics for checking it out. But you might want to post this in the 87-96 forum....those guys will have a lot more insight into the ZF.

 

Hey let me know how this swap goes for you! I am wanting to do this same swap in my 86 F150!

 

Sounds like a steal to me, keep us posted as I'm still looking for a ZF.

 

I just swapped in a zf into my 89 diesel. I just changed the oil and stuck it in, and it works great. The only problem areas I have heard of are case cracks in the bellhousing area, and reverse gear popping out, which if you believe previous owner, must be ok.

If you want it to shift well in cold weather, put Dexron automatic fluid in it like zf and Ford recommend.

 

the thing with manual transmissions, you dont know how they will work until you put torque through them. i swapped in a np435 before a zf, and 3rd gear howled like it was gonna grenade! the first zf i got from a junkyard had gear oil in it... bad sign of wear but i drove it anyway, the bearings clacked shortly after i swapped it in. the SECOND zf5 i bought remanned from zf for $1500. best 1500 i spent on a truck upgrade. it shifts great, it works, i can spin the truck to 5k rpm. for my truck being 2wd and 3.25:1 gears it can creep slower than my brothers bronco in 4lo and get much better mileage.

 

Thanks for the replies guys, was out of town for the weekend. I want to believe the previous owner (got my fingers crossed), so I guess I will just swap the fluid, ge the new clutch kit, and swap it in.

 

Alternative viewpoint: wouldn't it be easier to take it in and have it checked now while it's on the garage floor than to remove it from the truck later if it isn't working properly?

 

Yes, it probably would. But, the shops I have called have told me that unless I pay for a full rebuild, they will do pretty much the same thing I plan on doing i.e: check the fluid condition, pull the PTO covers and check for chunks, burned/discolored bearing, and check the shift linkage for obvious slop or binding while shifting.

 

If it was working when the truck was wrecked I'd just put it in and run it.

 

Thats the plan. He parked the truck after hitting a deer (or elk, can't remember), then a couple months later he blew the ring and pinion in the rear end after sliding off a logging road into a ditch. Going over to my brothers tomorrow (he's got the garage) to clean it up and take a look inside. Also dropping the flywheel off to get turned and picking up the clutch/pressure plate. So, hopefully, it will get swapped within the next couple weeks.