ZF5 Transmission Rebuild Part 2 - Reassembly! Episode 24, Project Brutus.

In this episode, I reassemble the ZF S547 4x4 transmission that I disassembled way back in Episode 12 of Project Brutus! This video covers the entire reassembly process from start to finish, including installing new bearings, synchros, setting the preload by using the correct shims, and all the applicable torque specs.
It took so long for me to get to reassembly because I was trying to source a good extension housing to replace the cracked one that was repaired twice. I ended up finding one back home in Texas for $400, but I had to buy the entire transmission to get it! FYI - the F Super Duty (and maybe the F450 and F550) is a heavy duty truck with 10 lug wheels and in a 2WD version, it uses the 4WD version of the ZF5 because it has a monster parking brake hanging off the back of the transmission. That's where I sourced my extension housing from.
If you found this video helpful and/or interesting, please hit the LIKE button and consider subscribing to the channel.
Thanks!
Scott Walters

[@PhelpsCycle]

Appreciate this made me far less fearful of tackling my zf5 s47. Thanks Joel

[@THEBULLETPROOFGARAGE]

Happy to help, Joel! Scott

[@aw9680]

I’m surprised you don’t have a hydraulic press. The harbor freight one is super affordable and I use it for all sorts of stuff. I smile every time I look at it. It saved me sooooo much headache over the years.

[@THEBULLETPROOFGARAGE]

I do have one at my home shop here in Texas. I didn't have my full complement of tools when I was stationed in Virginia. Thanks

[@blackpowderandbibles]

Thank you for making these videos. I knew doing a ZF couldn't be that tough but everyone I talked to seemed to say different. You proved them wrong. My 91 has been growling since I owned it, probably input shaft bearing. Now the one setting on the floor will get a rebuild to go in it. Thanks again!

[@MichaelJordan-jv6ic]

Good to see Brutus coming along. I'm glad that you found a replacement for the cracked housing.

[@THEBULLETPROOFGARAGE]

Michael - Me, too! I wasn't excited about using the cracked and repaired one. Scott

[@ryanyates3337]

Man you need more views! I've searched an searched for a actual step by step process and sir I appreciate it, good channel you got yourself!

[@ryanyates3337]

Watched a few vids before I even subscribed not outta skepticism I was just too into it been looking to long for someone who knows what there talking about without owning thousand dollar equipment

[@THEBULLETPROOFGARAGE]

Glad you found the video helpful, Ryan. Thanks, Scott

[@THEBULLETPROOFGARAGE]

@@ryanyates3337 - Thanks, Ryan. Glad to have you on board as a subscriber. Scott

[@randysrestoration]

Love the chainsaw content too! My first job was doing peeled popular and was really good money back in the day. (1973) They paid great for peeled vs non peeled. All done by hand. Cousin and I did 40 full cords

[@THEBULLETPROOFGARAGE]

Hey Randy - Thanks for the input on the chainsaw content! I grew up in the country so I've had a lot of experience with chainsaws, but haven't ever done it for $. Anyway, 40 cords is a bunch of wood! Scott

[@letherbuck]

Best rebuild vid yet Buddy, great job!

[@THEBULLETPROOFGARAGE]

Thanks! I appreciate it! Scott

[@Refertech101]

As a whackologist, I can tell you your table is giving you a good deal of grief that you may not be aware of, when driving do it directly on the concrete using solid wood to protect it, same for pulling, having it well secured allows much more of the impact energy actually removing it. I think this will do a great deal of making things go more smoothly for you!

[@THEBULLETPROOFGARAGE]

Yep, the HF table that I'm using is really handy, but it also has a lot of give to it, so I'm losing a lot of energy. Thanks for the input! Scott

[@lanecarter1097]

As a fellow whackologist I second this 😂

[@THEBULLETPROOFGARAGE]

@@lanecarter1097 Thanks!

[@linctexpilot8337]

Thank you for making these amazing videos!

[@THEBULLETPROOFGARAGE]

Glad you find the videos helpful! Scott

[@corbana4743]

That’s an awesome tutorial thank u so much ,

[@THEBULLETPROOFGARAGE]

Glad you found it helpful! Scott

[@MrUbiquitousTech]

Great tutorial, thanks for sharing. I need to replace the reverse sychros in mine some day, this will really help! Ugh, I have to say, I love old tools, my lathe is from 1908 for instance. But I hate old 2 strokes, lol. Not that I don't have some, but it's not by choice. Too much cardio

[@THEBULLETPROOFGARAGE]

Not everyone loves old chainsaws, but I'm a big fan! Good luck with the trans rebuild, Scott

[@WakeBoardMathew]

Would absolutely love the vintage chainsaw content.

[@THEBULLETPROOFGARAGE]

Thanks for the input, Mathew! Scott

[@royhaught9516]

I'll never have to rebuild a transmission, one of the reasons is it's above my skill level. But it's fun to watch somebody who knows what he's doing rebuild one. Good job !

[@THEBULLETPROOFGARAGE]

Thanks, Roy!

[@jackdaicole7595]

Heck yeah I'm a logger I drive a 86 f250 4x4 6.9 idi super cab and I collect old chainsaws and yes I use them.

[@THEBULLETPROOFGARAGE]

Excellent! Figured we had some crossover with diesel trucks and chainsaws! Thanks for the input, Scott

[@jackdaicole7595]

@@THEBULLETPROOFGARAGE quick question I have a 6.9idi it's tired. I'm planning on using the same method you did to build. How much to you have cost wise on the rebuild?

[@jackdaicole7595]

@@THEBULLETPROOFGARAGE I depend on my rigs and I am all hwy and off road! I stay in 4x4 because there are no roads where I work

[@THEBULLETPROOFGARAGE]

@@jackdaicole7595 - It was an expensive build for me, but that was because of all of the upgrades (injection pump, turbo, camshaft, etc) and some additional machine work. You can do a really inexpensive rebuild if you just use a ball hone on the cylinders, new rings, bearings, and gaskets, new valve seals. I think you can do it for less than $1,000. Thanks for the question, Scott

[@THEBULLETPROOFGARAGE]

@@jackdaicole7595 - Sounds like the perfect truck for you!

[@kellycowett6254]

A solid work bench would help you out

[@THEBULLETPROOFGARAGE]

Agreed!

[@kellycowett6254]

But I understand also that you have to make due with what you have so please don't take my comment the wrong way

[@travisbrookshaw371]

Great video but im confused when you said the shallow side goes up on the 5th and reverse hub. If you put the shallow side up, you will not get the snap ring on and also the hub would be smashed against the synchro ring

[@randysrestoration]

Great vid Scott! Looks like a lot of work. Curious what is the Orange Tool Box in background? I have had same junk tool boxes for last 25 yrs and in market to upgrade a bit.

[@THEBULLETPROOFGARAGE]

Thanks, Randy! The box is a Homak RS Pro with a stainless top - they're really quite nice and affordable, too! There's a long thread on the Garage Journal forums about these. You can buy them direct, but for a while, Napa had much better prices. I have another identical box back in Texas, and I'm planning to buy a third. Well worth the $. Scott

[@mattkenaston7180]

What are the rectangular holes on the top side of the bellhousing? Are there supposed to be covers of some sort over them?

[@kervinsommers1919]

Hey thanks for the video it has been very helpful as ive been rebuilding mine , where did you get the shim kit ?

[@THEBULLETPROOFGARAGE]

I found the shim kit online, but I can't recall who sold it. You should be able to find it with a Google search. Good luck! Scott

[@mrgearhead5087]

Where did you get your dial indicator? Would you have a revomendation on which one to use?

[@THEBULLETPROOFGARAGE]

I don't recall where I got it from. You should be able to find a highly rated one on Amazon. Summit Racing also has a pretty good selection. Scott

[@mrgearhead5087]

Thanks!

[@aw9680]

Was there a video on parts inspection?

[@THEBULLETPROOFGARAGE]

No, just the two videos - one on teardown and one on the rebuild. Thanks

[@MILLY10p]

My husband and I just put in a rebuilt zf5 trans and it won't shift at all. Any ideas ? New clutch , did fluid.

[@THEBULLETPROOFGARAGE]

Sorry to hear that. It's really difficult to diagnose problems via KZbin. Recommend joining the ZF5/ZF6 group on Facebook and posting questions there. Lots of great guys frequent that group. Good luck, Scott

[@okiedoke6373]

So what a lot of people don't know is there's two zf5 a long and a short gear ratio the short is for the diesel the long is for the gas I might have that backwards

[@THEBULLETPROOFGARAGE]

The gas ZF5 is wide ratio, close ratio for the diesel. Thanks, Scott

[@okiedoke6373]

So my question would be what would happen if you put the gas transmission behind a diesel because I didn't know that when I bought a transmission out of an F-550 had a gas engine what's the odds so now I have one that is for a gas engine and not a diesel the bolt pattern is the same I don't know

[@THEBULLETPROOFGARAGE]

@@okiedoke6373 the bolt pattern is different between gas and diesel engines.

[@kellycowett6254]

What did you say the preload specs were again please

[@alanlashley943]

Would like to know where you acquired the parts for the transmission rebuild. My dad had a 96 f250 7.3 power stroke with the 5 psd and he has messed the synchros up because of the bad bushing failure on the pedal under the dash and he kept forcing it in gear. That was a bad design on fords part but it is what it is.

[@THEBULLETPROOFGARAGE]

Hi Alan - I bought a kit off eBay for $278.99 - the seller was vital_parts. Good luck with the rebuild! Scott

[@alanlashley943]

@@THEBULLETPROOFGARAGE thank you!

[@THEBULLETPROOFGARAGE]

@@alanlashley943 Happy to help.

[@leezumwalt1163]

Really appreciate your level of detail. Forgive me if this is a dumb question…I’ve never rebuilt a transmission this complex. When you measured for the pre-load shim, you did not allow for a gasket. Then you used RTV. Is this because the RTV squishes out so much as to be negligible?

[@THEBULLETPROOFGARAGE]

Lee - it's actually an excellent question, but one correction -- as I mentioned in the video, I'm using an anaerobic sealant - Loctite 515. It remains in liquid form whereas RTV hardens into a rubbery texture. If I used RTV as directed - apply, install parts, run bolts down finger tight, and allow 1 hour to cure, then tighten bolts to spec - that would definitely make a difference in pre-load. However, with an anaerobic sealant, I really think any difference between fitting dry and fitting with anaerobic sealant is negligible. Thanks, Scott

[@leezumwalt1163]

Thanks Scott, now I know about anaerobic sealant! I assumed that meant it would not grow bacteria or something…

[@THEBULLETPROOFGARAGE]

@@leezumwalt1163 Happy to help!

[@Cody-pv5hy]

I see why you wanted to check preload especially with a case half from another trans, but with mine being all original I’m apprehensive about pulling new bearing races after they’ve been installed just to most likely put the original shims back in. Do you think I’m risking it by skipping that step?

[@Cody-pv5hy]

I know what I’m gonna do. I’ll put the original shims in, assemble it, BUT I’ll double check my preload by putting say, .010” shim between the case halves then check my end play and subtract the .010” to see if I have my .002-3” preload.

[@blazed85]

After seeing how many small pieces are involved I am now taking it easy on the gas pedal 😐

[@THEBULLETPROOFGARAGE]

It's actually not that difficult to rebuild, but taking it easy on the gas pedal is still a good idea! Scott

[@mikeharkins4825]

My 1995 5 speed f350 diesel is hard to get into reverse.

[@THEBULLETPROOFGARAGE]

Try shifting into first gear and then into reverse.

[@mikeharkins4825]

@@THEBULLETPROOFGARAGE mine works when I put it back into fifth let out on the clutch just till you engage just a very little, then back to reverse and it goes in.

[@THEBULLETPROOFGARAGE]

@@mikeharkins4825 ​ Might be time for new synchros. There's a ZF-5/ZF-6 group on Facebook with a lot of smart folks - facebook.com/groups/189400291474779 recommend you join the group. Scott

[@quadesmith1294]

Where did you get the shim kit? I’ve been searing everywhere online with no luck!

[@THEBULLETPROOFGARAGE]

I wish I remembered. There was only one place that had them. One of the retailers that sells ZF-5 parts.

[@THEBULLETPROOFGARAGE]

I found it - from Torque King 4x4 - part number QU20984 ZF 5 Speed Shim Kit

[@quadesmith1294]

@@THEBULLETPROOFGARAGE dang. That only one place is out of stock. Guess I’ll be calling them today. Thanks man!

[@THEBULLETPROOFGARAGE]

@@quadesmith1294 Happy to help. Good luck! Scott

[@aaronelliott5019]

@@quadesmith1294they still have some at Midwest transmission

[@MrSuperchargedv8]

what causes the common cracked case in the zf5 trans?

[@THEBULLETPROOFGARAGE]

Well, if it's a 2WD case, I think it's often caused by loose bolts from the transmission to the crossmember. On a 4x4, there's the added stress of the transfer case hanging unsupported off the transmission.

[@MrSuperchargedv8]

gotcha I just got into an obs super duty with the 5 speed but im looking to rebuild and hopefully upgrade some components while its open...any common problems I should look for or upgrades I should do?@@THEBULLETPROOFGARAGE

[@philipmcbride1903]

Will a zf5 hook up to the inline 6?

[@THEBULLETPROOFGARAGE]

Yes, a ZF5 will bolt up to a 300 six if you use the SBF version of the ZF5.

[@aw9680]

There were lots of 300 sixes with 5 speeds.

[@JohnSmith-kz1ll]

Your losing so much energy trying to hammer in those races and bearings on that table that has no back bone. Look at the part of the video where you took advantage of the soild concrete drive to hit the race in vs using that table. Big difference you need a heavier table that was hard to watch. Love Brutus so I will indure.

[@THEBULLETPROOFGARAGE]

Thanks for the tip, John!