Pulling it to rebuild here at the house...in the living room. Rotunda tool kit on hand.

Aside from driveshaft, downpipe removal, hydraulics... anything else? I have SMF already so that is good, will check clutch thickness. Bellowed upipes on the way. Will send shifter assembly out for the short throw conversion too.

Thanks for any tips!

 

Have help and remove the transfer case before you drop it, make it much more manageable.

 

I used ratchet straps to hold the trans after I pulled the crossmember and motor on the parts truck. They are very useful when pulling transmissions as well.

I agree with the removal of transfer case comment.

A trans jack wouldn't hurt either. You can usually rent one from any tool rental place.

 

Trans jack with a bag of sand on top of it

IIRC have to lift the tail up to get at the gears, hope you have high ceilings in your living room.

 

 

I have one of those trans jacks, they work great. I think it was $40 at China Freight. Operation seems straight forward, I will take pictures in case anyone wants to see one opened...hope it does not have too much damage inside.

 

I want to see inside and a step by step if you are so inclined.

 

 

Well it needs syncros and bearings for sure. I was towing a car and it was stuck in 4th. Even with shift lever back in neutral...I THINK the 3/4 fork is broken and it could not pop the sliding collar back to neutral. I put the shifter into 2nd and it popped 4th free like I dumped the clutch. :/ At least it was not stuck anymore. Drove it home towing with 1/2/5/R. Fun 2nd to redline then to OD, talk about belching smoke and SLOW as hell. Parked it until the tool set shows and I pull it out to break it down.

In any event, trans looks real simple from the ZF manual. Now that I have the collets to remove the old parts, should be easy to build. If anyone is interested in a copy of the collets, post up. I can run it past my fab guy to maybe make a run of 10.

 

That's a good idea!

Google: oil burner zf5 rebuild

 

Here it is...!

 

Maybe you want to rent that to members here.......

 

Hmm, now I could easily do that.

 

I will have a rebuild kit sitting here waiting. When your ready let me know. I am in BC but visit family in Washington state all the time.

 

Input shaft pocket bearing was dead. Not a shift fork. Explains why I thought it had 4th applied, that gear would not free spin as the bearing was not allowing it. Basically jammed it to keep spinning (applied). So good news nothing was chewed up in the process. The rollers fell out when I pulled the input shaft off the main shaft. Then I laughed.

You can see it on the top side of this pic, bottom is the counter shaft.



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