Ford zf6 speed rebuild part 1

[@michaelroth3471]

Watching this guy pound on those bearing races with a chisel drives me crazy!

[@DavidAyers-z9n]

Yes sir. I just heat mine and they fall in place.

[@kathleennawalt9855]

Dear Mr. Grease, Wow, nice job & "old school" workmanship. Using the tools at hand. Field work ! Sincerely, & Me, 😃.

[@danielprusa4356]

Man Thank you for making these.. I watched them over and over working on mine. Couldn't have done it without you.

[@smalltown6.09]

You have any good luck? Looking to rebuild mine before I put it in

[@ronhart4166]

I had to swap a case out from the old dual mass flywheels locking up and cracked the bell housing. I was surprised how heavy the gear assembly was !! I did not do much tranny repairs in my day. You are definitely a well rounded tech. Love the way you just jump right in. I also LOVE how quiet it is in your shop. I retired from a fast pace shop. The phone was always ringing and there was always some type of noise !!

[@jasondavis9354]

Next time heat your bearings to 200 F they will fall onto the shaft with no damage to the bearing. Every time you hit a bearing race it stresses it they are extremely hard but brittle!! I learned a few things in my few years of working with an old timer machinist

[@lobodelagarza5926]

Nice build video. All you have to do is heat the needle bearing race up and they fall off. Please always replace both races on the needle bearings. Also a clam shell puller us great to use. In that app. But great video. Also a brass punch and wd40 to in stall bearings and race. I do thus for a living everyday.

[@landybob8393]

Thanks for doing a how to that is actually a how to unlike some of the clowns out there. New sub here. Again thank you

[@edhog]

Mate, thanks so much. I'm a heavy duty tech. going to fix up an old 92 with the Zf5s42 in it. this video was a great in site to the contents of the case. never taken anything this small apart before and was curious about doing it without a press or the jigs. thanks again.

[@westerntruckandtractorrepa1353]

Big Box Wrench No problem , thanks for watching.

[@edhog]

grease monkey101 any tips with those or things to watch for? waiting on the bearing kit now. anything that should be replaced while it's open?

[@westerntruckandtractorrepa1353]

Big Box Wrench Look at the end of your input shaft where it rides on the pilot bearing and make sure it's not grooved, and look at the small mating teeth on the clutch collars and the gears they mesh with, if they are rounded off , replacing the bronze sychronizer ring won't help it will still grind, you will have to replace the collar and the gear. Whenever I open them up I change all the synchros and bearings.

[@edhog]

grease monkey101 great will do. got a master kit from ebay for $200 has every bearing and I think I have a 1991 as a doner for some stuff. fingers crossed

[@2491kridge]

Whenever someone says “I’m getting tired of screwing with this” while their lighting up a torch you know they mean business lol

[@Prariedog]

Awsome video Warren Thanks for sharing 👍

[@Jeepin199791]

Awsome video thanks and you are a pro with the torch I am not but a 3 prong china freight puller and some flat stock to make the links longer works great can make the puller as long as you need

[@JayDee-bz2ge]

When I rebuilt my manual transmissions I loaded all the parts in order onto a hammer handle, then re assemble in reverse as I replaced the few new parts. Quite a bit less BS than a automatic, but that ZF6 is kinda huge. I have a ZF6 in my F250, but I can't see it needing a rebuild for a long time. Get a hold of some (POWERUP lubricant) , I have a feeling you would appreciate the product....

[@twwtb]

33:17 Everybody has that trouble with snap-rings, even with the best snap-ring pliers you can buy. Best bet is to keep a lot of different ones around and pick the one that fits the best.

[@dandodds3681]

I worked in a Dodge dealership and had a customer brag to me about a weight scale slip that he had showing me a gross weight of 42,000 lbs. The truth was a Dodge 3/4 ton dually 4x4 with an N/V 5600. The input shaft was the weak link as he found out and received no warranty on the repair, even with the factory tools it was a pain in the ass to fix.

[@iowafarmer93]

the 7.3L had a ZF S6 650 while the 6.0L had a ZF S6 750. Discovered this while trying to swap some gears

[@kelbywatson509]

Swap some gears ? I’m currently trying to use the gearset from a ZF6-750 in ZF6-650 cases. Trying to swap my input shaft from the 7.3 transmission into the 6.0 transmission. I shouldn’t run into too many problems with that right ?

[@iowafarmer93]

@@kelbywatson509 the input shaft i believe is the gear that is different. The shaft is a different size. I know that was one of the gears I was trying to swap but it turned out the one from the 6.0 was junk anyway. Thats been four years ago so my memory is a little foggy. I think I mainly used a detent spring from first/second gear as mine had one missing or maybe I used the whole shift collar I don't remember. Most of the gears are the same except the input shaft I believe.

[@benjaminpankratz734]

@@kelbywatson509 did you end up doing that? I’m thinking of doing that right now because the reverse on my 7.3 zf6 went out but I got a zf6 from a 6.0

[@KG-yn9qi]

Depending on how far onto the shaft the inner race must go on you can use the old bearing inner race as a collar to hit on just have to stop before sticking the old race on shaft. So not hitting new bearing race etc... just a thought

[@jimball816]

i am building a tractor splitting stand so i can do a deutz d90-06 12 speed transmission. this video is very helpful. keep them coming & thank you so much

[@westerntruckandtractorrepa1353]

jim ball No problem , thanks for watching , and good luck with the Deutz.

[@jonka1]

@1:22:00 use the old race to beat the new race in. Saves any chance of damage and gives a more even force. Also wipe your hammer in case it carries any loose dirt.

[@rickytart1028]

Can't wait to see part 2

[@garylogan5460]

I have an nv4500 in my dodge with 350,000.I hope you do one sometime . good video ,thanks

[@stevekastner2825]

You gettin it there buddy. 🙂 pain in the arss

[@davidleet9501]

Very well done. Like the trick with the air hammer for putting races on. My dog is scared of lightning, but he also likes to watch when I weld, so I have to chase him off, too. Two questions though--how do you know the tapered bearing preload is right, by using the shims that came with it? Also, curious why you don't clean the outside of the case of all the dirt and grime, since you're obviously an excellent craftsman. Anyway, nice job, and hopefully I'll never have to rebuild my 7.3's 6 speed!

[@terryschramm9904]

Great video, thanks. My ZF 6 speed is difficult to shift. It won’t go into low and reverse sometimes and the other gears are stiff. Any advise?

[@AChrivia]

You should take any of your car, truck and tractor manuals like that and copy those to an external hard drive so you have a software copy of them and put your cds away. That way you can have all your manuals on hand in a hard drive to carry around and access them any time you need them by your computer. If you categorize them in the external hard drive it will all make work and life a bit easier on you. I do this for software I use to work on computers with and I always have all the software tools I need on hand any time I need them. I do a shitload of computer work and it makes life easier. If you need any tips to use computers to make life easier I'm willing to make suggestions.

[@AChrivia]

It sounds like there's someone else in the shop with you there in the audio. As I've seen in most of your videos, you usually work alone. Oh never mind, I see you're not alone. The dogs in there helping, haha.

[@jaylynch3205]

From watching it looks like you have to start pulling bearings even to get the input shaft separated from the whole assembly? Is that correct?

[@aarrontippens3231]

Where did you get the bearing snd synchro kit. I need one

[@sorryociffer]

Would you happen to know if the ZF6 crossmember is the same from 99-07? Want to install a ZF in my 05 4x4 Excursion

[@robertgetz8567]

Hey man I’m trying to work on one that someone had before me. When I split it I took the bellhousing off first and that came right off. When going to take the tail housing off I have it separated but the output shaft won’t come out of the case and I can’t get it to come apart…and advice or ideas?

[@blenheimfire]

If you send me address I will buy you a camera stand to help with camera. Love the videos that much! You can literally fix anything I'm convinced. I have a leaking ZF6 I'm about to pull apart thanks to your videos I have the confidence I can do it.

[@jd-uo8hc]

Field mechanic, getting shit fixed, making things happen, the guy you call when it needs to be done today... etc.. I'm very familiar those jobs.

[@stevekirby5419]

Have a zf 1999 f350 all together the space in the shifter won’t line up the last role pin in it is off a half inch need help

[@CUSTOMWORKS7.3PSD]

does anyone have input on the select able shim washer on the main input bearing, which shim is the best all around and do you do the bottom one where the pump runs also

[@HPHorsepowerful]

Hey great video. Where is the 4th gear, is it right by the input shaft the syncro that slides onto there? I just finished swapping a zf6 transmission into my cummins and it knocks very loud in 4th gear. Any idea what it could be? I just called the guy I got the transmission from and he said it never did that when he had it so don't know if I screwed something up while putting together.

[@robertramirez1766]

How was it swapping the zf-6 on to the Cummins? I've been wanting to do that to my cummins @HPHorsepowerful

[@calholli]

I need to swap my 2nd gear detent.... It pops out of gear very easily......... Can I do this with the trans in the truck? 02 f350..... I already pulled it/ split case and put in all new syncros''... I put it back in and months later--- the detent is now bad --- Why I didnt change them while it was out>lol... ? pretty dumb, obviously......... but where exactly is the 2nd gear detent and Can I do it while in the truck?? thanks. ....................... On pulling those gears with a long puller.... there is a special puller out there that costs $500.. but I didn't buy it of coarse... So what we did is take some 2" x 3/8" strap and a 3ft x 3/4 all-thread and make our own home made puller... and for the other set of gears... I had to pull them all three at once--- by which we made a home made press with a 32 ton jack bottle and pressed them all three off at the same time--- no heat........ It was pretty sketch- but once it finally broke loose... it was smooth sailing from then on...................... after watching your video--- I'm not exactly sure if my second gear teeth were a bit rounded and that's why it's poping out of gear.. or if it's just the detent??? but I'm not really worried about it.. I already developed a habbit of just holding it in 2nd gear so that it doesn't pop out......... But If i could fix it easy, I would.. any help or thoughts you could give would be appreciated-------- again.. can I change the detent with it in the truck? and would it even fix it?? or is it likely popping out because of rounded teeth? thanks again.

[@javiersernan9310]

Excellent Job!

[@dolnick7]

I've got a blue label ZF 6 speed manual transmission in my 95 C4 Corvette that needs service. Is this the same ZF6 that you're working on?

[@mikebolton2388]

no im pretty sure they are different cause first gear is 5 to 1 on this and corvette is like 2.7. so im pretty sure the internnals wouldnt fit. im trying to find kits for my black tag

[@jdmmmcgeary6882]

I followed your video when replacing input shaft bearing on my zf6, thank you for the help. When i got all done and installed i saw the two 6mm allen bolts that go from intermediate housing to case in step 11 on your computer (5:05 minuets in) left out on the floor of my garage! OOPS! I was curious if these are completely necessary for me to take transmission out again and disassemble or if the case bolts will hold everything fine without the 2 allen bolts?

[@CUSTOMWORKS7.3PSD]

I don't know if you got a answer, The 2 or 3 allen bolts are a alignment thing and to keep the front case from falling off during assembly. If you have it all together and the alignment pins where in the case your all set, no good or bad will come.

[@prevost8686]

Any transmission that has ZF on it needs to be scrapped. We had 10 ZF Astronics behind 12.7 Detroit’s. Spent over 100K in trans repairs just last year. Allison B500s are being retrofitted in them now.

[@TheHarry30rb]

Wayne Swicegood agree mate I spent $6000 to be rebuilt after falcon done milkshake( coolant mix in transmission oil) 2 years ago now it is again fluctuate speed on 50kms and 70kms . Can’t win German should start from fresh they don’t know how to build doesn’t matter what car from Audi to bmw that are just shit

[@nathanburgess4928]

yes sir👍👍

[@Tommy.McLean]

I've been wondering this for a while now and maybe you or somebody on here can help me. Could I rebuild my zf6 transmission without synchros so that way it shifts like my Kenworth with an Eaton 10-speed so I just double clutch or float gears?

[@getbent876]

You can float gears in any synchronized transmission it will just wear out the synchro if you do it poorly. Just use the clutch and then if someone else has to drive your truck and cant rev match correctly they can still drive it.

[@bennydiaz9065]

I got a 2000 7.3l power-stroke My reverse won’t go in all, what can be wrong? it’s only got 278,000 miles,

[@enriquemaisonet6475]

recommends it

[@johnathannutter8030]

Is the play in input shaft normal

[@JoseRodriguez-hl9zh]

Hola tengo uno 99 F3 50 4 × 4 y se me trabó la palanca de la transmisión si me puedes ayudar llámame gracias

[@landonsmith1818]

Thanks for the thorough and informative ZF repair. Where or from who did you order the parts kit?

[@dylanhowell1975]

How would i go about getting those instructions?

[@tedayoub5979]

Randy did you install the thrust washer on the main shaft correctly?

[@westerntruckandtractorrepa1353]

Who's Randy? Anyway. Not sure that was along time ago. I have a video on a 9320t funk 18 speed powershift, and another video on a 8320t 16 speed powershift rebuild , go over those really close and make sure I did those right too.

[@tedayoub5979]

Sorry I thought that's your name. I'm not criticizing you as a matter of fact your hands on video has been great. I just want to do the job once. Thanks

[@JP5150LBC]

This video is informative but some of the methods used are the same methos cave mans used... used rubber mallet on ALL internal parts minus roll pins

[@brettgoodman4360]

What brand is the 3 jaw puller you're using? I like the cage that holds the jaws tight.

[@westerntruckandtractorrepa1353]

+Brett Goodman Posi-lock and yes. I got mine at Napa.

[@rich1879]

grease monkey101: Thanx for the video, I ordered the rebuild kit for one of mine from eBay yesterday, I just ordered a 10 inch posi lock puller, I hope it's long enough, as, I couldn't tell how long is needed, I guess I will find out, but if not, I am just a good with a touch, smile. THANX AGAIN

[@TheShazteck]

Rich s did the 10 puller worked ? And where you got it

[@TheShazteck]

Which one will do both .. Would this one do both Posi Lock 110 Manual

[@JP5150LBC]

DO NOT USE A CHISEL TO SPLIT THE CASES... THERE ARE EAR YPUR CAN USE WOOD AND aA MALLET ON. if you damage that mating surface it will be more difficult to seal

[@benjaminpankratz734]

What was the website with the instructions called you used?

[@jocokrme]

You can use alldata diy for instructions to tear down and reassemble. Just Google alldata DIY.

[@ronhart4166]

What camera are you using ? I thought i heard you say phone. It is extremely clear on my end. I could see the pits in the bearing really well.

[@westerntruckandtractorrepa1353]

Ron Hart I was using my phone then , I have been using a GoPro here lately. I think for low light situations the phone worked better.

[@ronhart4166]

I thought that is what I heard you say. Looked as good as a DSLR. !! I watched a couple of your videos with the go pro and you could see a little slow fps. You may want to try protune or adjust the frames per second. I have really enjoyed your videos . You explain things very well . Thanks for sharing.

[@jesseosorio2851]

name of the program you use please

[@enriquemaisonet6475]

l greeting the texa diagnostic is the closest to the original and does a lot of functions

[@freshlymade3932]

Wanna do another zf 6speed? I'm having trouble...😥

[@rocsvt1]

where do you bought quality parts for this trans

[@Mikael5732]

I am about to rebuild my zf5 s42. Where can I get the program you are using but for the ZF5 trans?

[@westerntruckandtractorrepa1353]

www.google.com/url?sa=t&source=web&rct=j&url=www.vaglinks.com/Docs/Catalogues/ZF.com_S5-42_47__47M_Service_manual_.pdf&ved=2ahUKEwiqtKf0zsfaAhUKx1kKHSocA0UQFjABegQIBRAB&usg=AOvVaw1Gh0ZllOcKDKfpKCECBGba

[@Mikael5732]

western truck and tractor repair thank you sir for that information and that fast reply. Good video also. 👍

[@MrSanblast]

Can someone help me with small bearing on backside of input shaft? It was the only bearing not shown in the video. Mine is an FA. They all seem the same. Truck is a 2006 F350 60 manual. Five eight five (315-5690)

[@MrSanblast]

This bearing seems to be part of the spline?

[@ppschafer50]

how far into into disassembly do you have to go to just change out the imput shaft?

[@westerntruckandtractorrepa1353]

Phil Schafer Pretty much all the way, separate the case and you can pull the interlock and forks off then pull your input off the main shaft

[@ppschafer50]

Any advice for setting imput bearing preload? Or place to dowload service manual?

[@westerntruckandtractorrepa1353]

Phil Schafer I have the Ford oem manual , you may not want to pay 300 for a disc like I did, try EPC catalogs.com.

[@n3zyd]

fun fact also used in the C4 corvette from 89 to 96 good for 500 foot pounds or 640nm

[@westerntruckandtractorrepa1353]

+n3zyd Good to know.

[@Iammastercheif1]

These are very different transmissions. The C4 had the ZF s6-40. This is the ZF S6-650. This unit is much larger and much stronger, would never fit under the Corvette, and is good for well over 1000 lb-ft

[@hanrohenning6109]

Where is number 5 and 6 gear located

[@jimbuford4147]

Do you have to pay for those repair instructions you use and if so where can I get them? Thanks

[@westerntruckandtractorrepa1353]

Jim Buford That particular set of instructions I bought directly from Ford. It's a cd rom disc that covers all makes and models for that year . They were 300.00 a piece.

[@hatrack8846]

Don't buy from that link. I did and it has nothing on how to fix gears and stuff. I found the manual on emanualonline.com then.

[@krisdavis1083]

Had my 04 zf6 rebuilt maybe 20k ago. Trans just went out again. Drive gear burned up and started chipping away. I have south bend dual disk clutch. When trans was installed the system was flushed and cleaned. But was told the dual disk could be causing to much heat and causing the drive gears to burn up. Has anyone ever heard of this? Or am I just getting the run around. Thanks for any help.

[@westerntruckandtractorrepa1353]

That's bullshit .

[@krisdavis1083]

Ok thank you. That's what I thought. Dont have a lot of transmission expertise so figured I'd ask.

[@DaddyForeverYess]

i nice 1 1/14 in brass drift with knurled handle

[@ferminretanameza8665]

Used oil 90w fleetrite make lower temp and main bearing no blue color steel burned

[@hadihassan745]

I have zf ak 6-80 , I need book for transmission, can you help.

[@westerntruckandtractorrepa1353]

+Hadi Hassan I am sorry I do not have that one.

[@hadihassan745]

Thanks man.

[@andreluis90969]

It's a ZF S6-40, right? How expensive is to fully rebuild one of these beauties?

[@westerntruckandtractorrepa1353]

andre luis gusmao The bearing and synchronizer kit is 350-400 dollars, that's if you don't need input shaft or any gears.

[@andreluis90969]

Isn't so expensive. And the shaft and/or gears, how much? I'm from Brazil and there's no spare parts to sell here. I saw in a website the repair kit for 2000 dollars! Is that correct? www.manualtransmissionpart.com/S640-bearing-synchros.html

[@westerntruckandtractorrepa1353]

+andre luis gusmao The input shaft is like 170 dollars and the gears it really depends on which ones you need.

[@westerntruckandtractorrepa1353]

andre luis gusmao If you go to www.tbtrans.com there is a complete list of the zf6 speed parts and prices.

[@westerntruckandtractorrepa1353]

andre luis gusmao Oh and no this is out of a 7.3 powerstroke, the zf s640 is in Corvettes I think.

[@armandoorozco2212]

How much was the total cost on this rebiuld?

[@westerntruckandtractorrepa1353]

+Armando Orozco Transmission and engine was about 12,800 . That's parts and labor.

[@westerntruckandtractorrepa1353]

Armando Orozco The Transmission buy itself was around 1,800.

[@armandoorozco2212]

Thanks, I have an 2002 F250 7.3L and my transmission has around 270K. Im preetty sure it needs new bearings and most likley the input shaft. I dont know where youre located but im in chicago IL and id like you to do the sme kind of job here

[@westerntruckandtractorrepa1353]

Armando Orozco Well I am quite aways from you. I am located in Southern Oregon.

[@armandoorozco2212]

grease monkey101 I'd drive the truck out there but I don't want to risk it

[@MyChannelJZ]

Where can I find the software?

[@shanewood7942]

Happen to have a good 6.0 input shaft you would sale.

[@JP5150LBC]

3 allens are for pre early 99

[@Dontknowwhattouse]

I got new and used parts for 5 or 6 speed ZFs and most manual transmission parts. Let me know what you need

[@MrSanblast]

I am trying to change the small bearing on backside of input shaft. Im not sure how to change it. IS it part of the spline. th=is video does not show how to replace it. do you have the bearing for this? my transmission is FA.

[@MrSanblast]

Im in need of a Koyo ST 2455 tapered input shaft bearing (backside) for my manual 6 speed F350.

[@Dontknowwhattouse]

@@MrSanblast For some reason I never seen this message but yes I have the bearing

[@Dontknowwhattouse]

@@MrSanblast I have it as well

[@davidsoltwedel7085]

anything special to get the two housing's off of the center support plate

[@JoshWilliams-]

do you have any videos of a zf 5 speed transmission rebuild? I'm trying to do mine but haven't found a good video yet.

[@westerntruckandtractorrepa1353]

Josh Williams I have done a few of those , that was before my video making days, sorry.

[@slomango7927]

Can I send you my zf 6 speed assembly for bearings and syncros???

[@westerntruckandtractorrepa1353]

Grocery Getter Sure, can you send me a private message on KZbin. We can exchange some info.

[@slomango7927]

grease monkey101 I don't know if it's me or you but I don't see the option to private message you on your about page. My email is [e-mail] if you use email. Thanks

[@westerntruckandtractorrepa1353]

Grocery Getter ok

[@perryreasch1209]

take his students out in the field with him ?

[@ابواحمدالحربي-ج2ك]

Hi , I want this book ,where are find this book

[@westerntruckandtractorrepa1353]

+أبو أحمد الحربي I got that at a Ford dealer

[@hatrack8846]

Don't buy from this link. I did and it has nothing for repairing these transmissions. I found a manual on emanualonline.com then.

[@ferminretanameza8665]

Check Lash teeth housing washer our shoap y water

[@perryreasch1209]

He should be a instructor at a college ?

[@ervinbrew]

Thanks for the vid! I have my zf6 apart trying to figure out why it clunks going into first and reverse. Sometimes it' very hard to get into these gears. I've tried ford hyd cyl and new clutch kit. I think for some reason the input shaft is spinning in neutral and possibly the syncho ring is not acting right. Have you seen this problem?

[@Marqistador1470]

ervinbrew that’s usually a hydraulic issue, not a transmission gear issue