ZF5 Transmission Noise
 

I've just noticed a strange noise that appears to be coming from the transmission. It is present at all times but not in 4th gear or when you press in the clutch. I tried to capture it on a video. Hopefully you can hear it.

How about when stopped and clutch in then out?

4th locks input shaft to main shaft for direct aka 1:1. Besides internal trans noises are usually way worse sounding...from personal experience ha

Drop inspection plate and snoop around.

No noise in neutral, clutch or not. It is only while in gear and clutch engaged. I know I need to drop the inspection cover, but will be a little difficult to take a peak with it in gear. :eek:

Try it with transfer case in neutral first.

Have you verified trans is full?

Been so busy this week I forgot about this. I did try it with the tcase in neutral and it does not make the noise. It literally is only while in gear and moving. I'm guessing you can't hear it very well in the video, but is does change with the RPM of the engine.

I am not by my PC with good speakers, my phone one has real poor one.

Only thing that comes to mind if quiet in 4th and noise in all others is a dying input pocket bearing. This bearing inactive in 4th as main shaft and input shaft are locked as a unit. This was my issue but it was always loud since the day I purchased...until failed.

Did you shift through all gears while T case in neutral?

Yep, all gears are quiet in neutral.

Here is another variable...does it do this in 4hi too?

I suspect the input shaft bearing. Pull the transmission and run it with a drill. Recently had a really loud set of bearings. Sort of a clicking noise. Took it apart and the bearings on the secondary shaft were a bit notchy although new.

Alright, so this noise has gotten worse. I finally pulled the trans and have found the following:
The input section of the clutch disc had a lot of movement. Not sure if this is normal or not.

And the trans input also seems to have some play.

Split the case.

It's not that bad of you just do bearings and seals.

It looked like it shifted fine.

It does shift fine.

Well, I just drained the trans. If I was paning for gold, I'd be happy. :-arrgh
https://cimg0.ibsrv.net/gimg/www.for...d0dec784da.jpg

Well, I found the problem: the output shaft bearing is toast. All the gears look good, so a new set of bearings should get this back on the road.

https://cimg8.ibsrv.net/gimg/www.for...9c6aa10caa.jpg
https://cimg4.ibsrv.net/gimg/www.for...c2c53f1985.jpg
https://cimg6.ibsrv.net/gimg/www.for...3b7fa1aa7f.jpg
https://cimg7.ibsrv.net/gimg/www.for...19a1786125.jpg

Is midwest trans the place everyone recommends for ZF parts?