OBS ZF5 2nd gear Servo issues - Ford Powerstroke Diesel Forum
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Old 07-11-2014, 10:26 PM
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OBS ZF5 2nd gear Servo issues

My truck will not go into 2nd when downshifting, all tell me it sounds like I have a bad Servo. If the remainder of the trans working fine is it worth repairing the one Servo or should I rebuild entire trans, buy used or buy rebuilt? I have no experience with these trannys and if it is not too difficult to repair I may be able to but if it is really complicated then I would need to take to a trans shop. I live in Carroll County md and looking for a good shop in Carroll Co / Baltimore area / Frankford (near Bethany Beach) Deleware I spend time in all these locations and can bring it to a shop if anyone has good fair shop, let me know. Thanks
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Old 07-12-2014, 07:41 AM
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The synchro is bad won't go in or grinds going in. Either way it sounds like a synchronizer. The entire Trans has to come apart. I know it takes a press and some special tools. If it's just the one try double clutching it may help. All of the synchro snare out in my 97 I shift without the clutch and just match rpms. Been that for a year will go many more probably.


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Old 07-12-2014, 08:07 AM
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I rebuilt my tranny last year and needed no specialty tools or a press.

You do need a large range of pullers and separators to get all the bearings and gears off the main shaft.

I then used a toaster oven to heat the new bearings and gears. They slid right on.

Not too difficult, but it's very involved.


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