ZF tranny swap preparations - Ford Powerstroke Diesel Forum
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post #1 of 6 Old 03-07-2009, 07:28 PM Thread Starter
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ZF tranny swap preparations

its been a LONG time since I've pulled a tranny. im gonna be doing it on my back () and im tryin to make sure ill have everything i need.

i have pleanty of tools, gonna get a tranny adapter for my floor jack. i still have the hydraulic line tool from my ranger clutch job in highschool, will my PSD use that same tool?

how heavy are the ZF 5 speeds? anything else I need to do?

was plannin on disconnecting batteries, draining tranny, take shifter out, markin drive shaft & removing. un hook clutch lines and speedo sensor, support engine & tranny. un bolt mount and crossmember, un do bellhousing bolts and remove!

also swapping flywheel for a single mass, new one seems to come with new bolts. that should be pretty straightforward.

any tricks or anything im missing?

-ReD

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post #2 of 6 Old 03-07-2009, 07:56 PM
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Tranny Swap

Sounds like you got it figured out... just dig in, the job aint that bad.

And gettin rid of the dual mass is a great idea.

Good luck with the swap

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post #3 of 6 Old 03-09-2009, 08:40 PM
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you don't need to fool with the clutch line, just pull the clip that holds in the slave. Oh yeah, the ZF is a HEAVY MF'er. Disconnecting batteries is a good idea, you may need to unbolt the starter too (not sure.) Only wiring on the trans should be the reverse switch.

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post #4 of 6 Old 03-10-2009, 09:40 PM Thread Starter
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what about the pilot bearing? special tool needed to R&R? (Remove & Replace)

-ReD

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post #5 of 6 Old 07-14-2010, 06:54 AM
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the issue im dealing with is the truck not starting because of the nuetral or clutch sensor. im missing that wire harness that hooks up to the clutch pedal sensor. I thought i had everything, guess not.

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post #6 of 6 Old 07-18-2012, 08:07 AM
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I believe you need a sliding hammer with the bearing adapter to remove the pilot bearing and replace, sound easy but I have heard this is the worst job to do.. I am currently tearing into my truck and dropping the tranny because my throwout bearing blew up on Sunday lol inspection plate removed and the balls came flying out lol..fun stuff..this job isnt fun..but not the worst in the world to do...take it from a girl..if I can do it..yall can do it lol I almost have the tranny ready to come out, Thankfully I have help tomorrow morning to drop the tranny fix her and put her back in...Good luck on your rig

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what about the pilot bearing? special tool needed to R&R? (Remove & Replace)
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