ZF5 Reverse Popping Out

[7.3 on 40s]

Did my research and found that its common for my 97 350 to have the issue where reverse does not stay engaged very well. Wondering if any of you can give some advice on whats the best way to grind the least. I have new correct fluid in the trans. Always make sure to be completely stopped. I usually go 1st then reverse. I would say 80% of the time im good and 20% it pops out when letting out clutch. It does not grind when going in as if the blocker ring is worn it just doesnt stay engaged all the way sometimes. I would imagine its a worn syncro or a worn rev. gear. but with the 10-20% grinding i dont think i want to rebuild/replace the trans. just yet.

Do you all have any tricks you use to keep the rev. grinding to a min.??

Do you know what goes wrong in these transmissions to cause this???

[Diesel_brad]

Pop[ing out of gear is typically worn bearings

[7.3 on 40s]

Really? It also seems that when it does pop out it feels a little more crappy when going in like the syncro isnt locking all the way on to the gear.

When its in it does not pop out no matter what speed im going or no matter what bumps im going over.

Question. Is there a manual trans. upgrade for these trucks. As in a better trans. than the ZF5 that bolts up to the 7.3

[PSDBuilder]

Just a idea but my 97 I had it was a bear to get in reverse I always went 4 to r . One of my probs was the bushing on my clutch pedal.. Have u checked the play in yours

[7.3 on 40s]

Yeah i go 1st to rev or 4th to reverse etc. My clutch pedal assembly is actually all new. Its not bad getting it into reverse. Fairly easy actually just sometimes when it pops out it feels a little extra notchy when going in leading me to think some roughed up syncro teeth.

[Diesel_brad]

Originally Posted by 7.3 on 40s

Really? It also seems that when it does pop out it feels a little more crappy when going in like the syncro isnt locking all the way on to the gear.

When its in it does not pop out no matter what speed im going or no matter what bumps im going over.

Question. Is there a manual trans. upgrade for these trucks. As in a better trans. than the ZF5 that bolts up to the 7.3

While the ZF does have its issues, it is a pretty reliable trans and cheap to repair. You can buy EVERY bearing, sync and seal in the thing for $250. It takes a COMPETENT trans shop a day to pull the trans, repair and reinstall. So you would be looking at 850-1000. That would be the time to put a clutch in too

[7.3 on 40s]

Sounds good. Was a corvette tech for a chevy dealer years back. Have done my share of repairs including auto and manual transmissions. Looking under there pulling the trans. doesnt look as bad as i thought for a diesel. I think ill keep driving it the way it is and baby reverse. When it gets worse or i have a problem with another gear ill pull it and look for a good deal on a whole unit. My last trans. i rebuilt at home was in a 97 cobra and i had to r&r 3 or 4 times because i kept shimming the input shaft incorrectly.