ZF 6 speed problems
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Senior User
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From: NE TX
ZF 6 speed problems
I just changed clutch master cylinder in 2002 F250 4x4 w/ PS and 6 sp. It has 70K miles. Dealer doesn't want to warranty transmission. Is 36K all to expect from Ford on Powerstoke transmissions? Reading other threads and experience in other trucks, my clutch release bearing is bad. But truck sometimes wants to pull forward in neutral, doesn't go into gear easily and sometimes goes forward in reverse. Other times it backs up. So I assume I also have trouble in the transmission. I am looking for web assistance, .pdf service manual on 6 sp, or .html. Any assistance? Thanks!
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Joined: Mar 2001
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From: Charlotte
ZF 6 speed problems
Tim
I hate to say it but forget the dealer. Ford has had countless problems with the clutches and hygraulics in the zf6. Once the tsb is done for the hydraulics I would pull the OE ford clutch out before serious damage is done and install a Luk unit. Several owners have had to replace input shafts incurring very expensive repairs. Let me know if you have any questions.
I hate to say it but forget the dealer. Ford has had countless problems with the clutches and hygraulics in the zf6. Once the tsb is done for the hydraulics I would pull the OE ford clutch out before serious damage is done and install a Luk unit. Several owners have had to replace input shafts incurring very expensive repairs. Let me know if you have any questions.
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From: NE TX
ZF 6 speed problems
Thanks for the reply. I found information on LUK clutch and pulling the transmission at https://www.ford-trucks.com/contents...tch%20Upgrade.
I can get rebuild manuals for most Eaton, Fuller, Road Ranger transmissions downloaded for free but I can't find one for the ZF 6 speed for diesel. I log and we operate and repair heavy tractors and trucks often. I'm sure something besides the clutch release bearing is bad. I still haven't looked up prices or locations for the LUK. I'm trying to find rebuild parts for the transmission and service manual so I can install them. I found a Ford number on the trans and a parts list number but nothing shows up on Google. What is the name/number for the 2002 ZF 6 speed for PS diesel? Any ideas to get rebuild info or pictures? Prices for LUK or rebuilt transmissions?
I can get rebuild manuals for most Eaton, Fuller, Road Ranger transmissions downloaded for free but I can't find one for the ZF 6 speed for diesel. I log and we operate and repair heavy tractors and trucks often. I'm sure something besides the clutch release bearing is bad. I still haven't looked up prices or locations for the LUK. I'm trying to find rebuild parts for the transmission and service manual so I can install them. I found a Ford number on the trans and a parts list number but nothing shows up on Google. What is the name/number for the 2002 ZF 6 speed for PS diesel? Any ideas to get rebuild info or pictures? Prices for LUK or rebuilt transmissions?
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Senior User
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From: NE TX
ZF 6 speed problems
I got info. on LUK at www.dialaclutch.com/latepowercont.htm
If there are better places to buy please let me know. The instructions were simple enough if everything goes as planned. I have changed clutches before but not on a Powerstroke and I'm no expert. I'm not a mechanic either. I can replace parts but I've got a lot to learn about diagnostics. Thanks.
If there are better places to buy please let me know. The instructions were simple enough if everything goes as planned. I have changed clutches before but not on a Powerstroke and I'm no expert. I'm not a mechanic either. I can replace parts but I've got a lot to learn about diagnostics. Thanks.
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From: NE TX
ZF 6 speed problems
I got the transmission out. The clutch looks good. Pressure shows some wear where release bearing runs and one finger is chipped about halfway to center. Release bearing seems to be okay but I know they can be deceiving. I haven't taken the transmission apart yet but I still believe the problem to be with shifter. I have the gearshift off and top part off. It doesn't move and should slide easily (I think). The FixitCD came and printed lots of pages and pictures on the transmission. It covers all trucks, SUVs and vans for 2001 and some 2002 models like Mountaineer. If the other sections are as thorough as the one on ZF 6 speed, it could train Mr. Fordwrench. $20 total well spent. Thanks everyone.
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From: NE TX
ZF 6 speed problems
My trans is S6-650 ZF for Ford diesel. Only Ford's number is on the tag though. As best as I can tell this transmission is no longer available. Late 2002 with 6.0 should have M6HD-C transmissions. Gasoline engines keep the S6-650 ZF. I need a mainshaft, countershaft, 6th gear, detent plugs, some thrust washers and all seals for this S6-650 and a lot of luck putting it back together. If anyone knows a good source for late model transmission parts or a high quality rebuilder, please let me know. I am glad my other trucks are gasoline powered.
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Laughing Gas
Joined: May 2003
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From: Scenic Wisconsin
ZF 6 speed problems
Tim -
I just had the trans in my older Ranger replaced, and I happened to be working in the small town of Zumbrota, Minnesota (it's about 50 miles south of the Twin Cities). Apparently, a large percentage of the shops in at least the Midwest buy their rebuilt transmissions from a couple of big shops in Zumbrota. Try Zumbrota Bearing & Gear (507) 732-7994 - they're nice people. They ship nationwide, too.
I just had the trans in my older Ranger replaced, and I happened to be working in the small town of Zumbrota, Minnesota (it's about 50 miles south of the Twin Cities). Apparently, a large percentage of the shops in at least the Midwest buy their rebuilt transmissions from a couple of big shops in Zumbrota. Try Zumbrota Bearing & Gear (507) 732-7994 - they're nice people. They ship nationwide, too.
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Post Fiend
Joined: Jan 2002
Posts: 5,859
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From: USA
ZF 6 speed problems
Tim ,where in texas do you live?
There are a couple zf- distributors in TX.
As for the 6speed ,its a pain to rebuild , torqued
for endplay clearances which are a pain in the butt
Biggest problem is we forget to change the fluid often ,it use atf as you know which in my opinion its to light of a fluid for this tranny.
Mine was replaced under warranty brand new on my 02 truck (input shaft and pilot bearing destroyed)
If you need more info on distributors let me know
Rich
There are a couple zf- distributors in TX.
As for the 6speed ,its a pain to rebuild , torqued
for endplay clearances which are a pain in the butt
Biggest problem is we forget to change the fluid often ,it use atf as you know which in my opinion its to light of a fluid for this tranny.
Mine was replaced under warranty brand new on my 02 truck (input shaft and pilot bearing destroyed)
If you need more info on distributors let me know
Rich
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From: NE TX
ZF 6 speed problems
I believe I will get a rebuilt transmission. My brother has sources for salvage trans and rebuilt. I like to compare warranties and quality more than price. This is something I prefer not to do very often. I believe I could rebuild the trans even without the proper tools if I had some help but I am not willing to pay for parts, give up my labor (I'd rather be doing something else!) and risk pulling the trans several times to get it right. Someone else deserves a job. I did know ZF had a distributer in Dallas around 1992 that sold reman. trans around Dallas-Ft. Worth and advertised in "The Quarter Horse Journal". I still receive the magazine but have not seen the ad in a long time. My brother's best price was $2500, mine has been $2725+$1000 core. I live 70 miles west of Texarkana, 150 east of Dallas, 200 miles south of Oklahoma City. There are local shops around but no one can have much experience with these trans. Best I can tell Ford went to M6HD-C behind 6.0 PS. Gasoline engines keep the S6-650 (and GM trucks). Let me know if anyone knows a good place to buy. I'd rather drive to pick it up and drop off the core (less than 200 miles one way). Thanks.
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From: NE TX
ZF 6 speed problems
I bought a rebuilt (by ZF) trans from Blumenthal MFG in OKC for ~$2400 + $85 shipping. It arrived overnight in a box and the trans was full of fluid. I changed the release bearing and pilot bearing. The original trans was low of fluid. Once I installed the new trans and cranked the engine I found a leak on the cooler line. I ordered it from the dealer for $25. I did not replace the clutch or pressure plate. This is my father's truck and he didn't like spending so much on a 50K miles truck. The clutch disc was fine. 2002 is an updated clutch disc but it still only has 3 springs. The stock flywheel was already solid so I don't think it is a dual mass but I may be corrected. There was no lining or springs on the flywheel like some I've seen before. I really wanted to go with LUK parts but didn't see the need. By the way several companies offered to rebuild my case for $3100. Both shafts probably costs $1600 and I'd still need seals, gaskets etc. I feel good about Blumenthal. They do have a website and offer probably every trans imagineable. I received excellent service and would recommend them to anyone. Thanks for everyone's help.
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