ZF5 problems - Ford Powerstroke Diesel Forum

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post #1 of 13 Old 02-06-2014, 07:27 PM Thread Starter
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ZF5 problems

This summer I rebuilt the ZF 5 speed transmission in my 96 F250 psd. When I take off in first gear at idle it has a "growl" to it, but if I take off in first at about 1,000 rpm there is no noise. Any ideas on what is causing the growl? I have heard that it is a fairly common problem. Also, the motor has 353,000 miles on it, idk if that matters or not. Any advice would be greatly appreciated!

96 4x4 F250 Xl Ext. Cab Long Bed 7.3 Powerstroke rebuilt 5 speed, rebuilt Front Axle, T500 HPOP, stage 1.5 injectors, 6-position chip from TS, quick spool housing, WW2, E-fuel, gauge pillar w pyro, boost, and fuel pressure
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post #2 of 13 Old 02-06-2014, 07:38 PM
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Do you have a Single Mass Flywheel and clutch in it? If so, it's probably what we call "gear rollover noise" and is much more noticeable with the SMFW. My ZF factory reman'ed tranny did the same thing. Cheers!

1997 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, External Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed

SOLD - 1994 F350 CC DRW 2WD PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, DPPI DP, Bilsteins, $12 AIC, Coolant Filter, Explorer Overhead Console, A-Pillar w/ISSPRO Black Ice, EV Boost, and EV Pyro, Modified Pedestal, Gutted EBPV.
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post #3 of 13 Old 02-06-2014, 08:13 PM Thread Starter
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I'm not sure, how would I be able to figure that out?


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96 4x4 F250 Xl Ext. Cab Long Bed 7.3 Powerstroke rebuilt 5 speed, rebuilt Front Axle, T500 HPOP, stage 1.5 injectors, 6-position chip from TS, quick spool housing, WW2, E-fuel, gauge pillar w pyro, boost, and fuel pressure
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post #4 of 13 Old 02-07-2014, 06:11 AM
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Yo would need to remove the inspection cover. The Dual Mass Flywheel will have 2 masses that can be slightly counterrotated against each other (about 5/8") and the dampening springs are located in the flywheel instead of the clutch disk. The SMFW will be a one-piece flywheel with the dampening springs in the clutch disk hub instead of the flywheel. Cheers!

1997 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, External Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed

SOLD - 1994 F350 CC DRW 2WD PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, DPPI DP, Bilsteins, $12 AIC, Coolant Filter, Explorer Overhead Console, A-Pillar w/ISSPRO Black Ice, EV Boost, and EV Pyro, Modified Pedestal, Gutted EBPV.
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post #5 of 13 Old 02-07-2014, 06:22 AM Thread Starter
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Ok, then it is certainly a SMFW, so the noise is nothing to worry about then? The transmission shifts good, no grinding or anything.


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96 4x4 F250 Xl Ext. Cab Long Bed 7.3 Powerstroke rebuilt 5 speed, rebuilt Front Axle, T500 HPOP, stage 1.5 injectors, 6-position chip from TS, quick spool housing, WW2, E-fuel, gauge pillar w pyro, boost, and fuel pressure
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post #6 of 13 Old 02-07-2014, 07:02 AM
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If it is only down at very low (almost lugging) RPMs, then you should be fine. Cheers!

1997 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, External Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed

SOLD - 1994 F350 CC DRW 2WD PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, DPPI DP, Bilsteins, $12 AIC, Coolant Filter, Explorer Overhead Console, A-Pillar w/ISSPRO Black Ice, EV Boost, and EV Pyro, Modified Pedestal, Gutted EBPV.
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post #7 of 13 Old 02-07-2014, 07:30 AM Thread Starter
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Yeah it is, thanks! I am assuming that a Dual mass clutch has better performance? What would be the advantage of switching clutch types?


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96 4x4 F250 Xl Ext. Cab Long Bed 7.3 Powerstroke rebuilt 5 speed, rebuilt Front Axle, T500 HPOP, stage 1.5 injectors, 6-position chip from TS, quick spool housing, WW2, E-fuel, gauge pillar w pyro, boost, and fuel pressure
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post #8 of 13 Old 02-07-2014, 08:32 PM
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No, the Dual Mass are problemmatic, expensive, and are a weak point. Most folks end up with the single mass setup. You do get increased gear rollover noise, but its a truck! I just learned to live with it and not lug around as much. Cheers!

1997 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, External Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed

SOLD - 1994 F350 CC DRW 2WD PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, DPPI DP, Bilsteins, $12 AIC, Coolant Filter, Explorer Overhead Console, A-Pillar w/ISSPRO Black Ice, EV Boost, and EV Pyro, Modified Pedestal, Gutted EBPV.
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post #9 of 13 Old 02-07-2014, 08:34 PM Thread Starter
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Haha ok, thanks for the info!


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96 4x4 F250 Xl Ext. Cab Long Bed 7.3 Powerstroke rebuilt 5 speed, rebuilt Front Axle, T500 HPOP, stage 1.5 injectors, 6-position chip from TS, quick spool housing, WW2, E-fuel, gauge pillar w pyro, boost, and fuel pressure
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post #10 of 13 Old 02-08-2014, 07:44 AM
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There is no "dual mass clutch". A dual DISC clutch is a performance upgrade, one that really isn't worth considering unless you're pushing a LOT more horsepower out of the engine. A single-MASS FLYWHEEL is a remedy for the peril of the dual-mass coming apart and grenading your tranny. Two completely different parts, either of which can be dual or single.
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