Zf6 output shaft replacement difficulty - Ford Powerstroke Diesel Forum
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Old 05-28-2014, 05:18 PM
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Zf6 output shaft replacement difficulty

Broke the teeth off of the output shaft and was wondering how hard it would be to replace just that. I already have the tranny out and the part in the garage. I have rebuilt a 4r100 with my dad before, but haven't ever been inside a zf6.

Thanks for all the help
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Old 05-28-2014, 06:33 PM
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I've heard its a bear. But I have no idea. How did you break it.

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Old 05-30-2014, 07:12 AM
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That's what I've been hearing

We had to snatch my grandma's diesel excursion out of a good sized ditch a while back and it just broke a few days ago when my dad was leaving for work.

My guess it that some of the splines broke when he pulled her out and the rest just broke over time.

Thanks for the reply
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Old 05-30-2014, 07:47 AM
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You have to separate the case halves and disassemble the shafts.
You need to replace the lower counter shaft gear opposite of damaged gear or
you'll be doing it again soon. I done had that problem before cost me 725 for trans repair.
You also have to have endplay set during reassembly. If it's the input shaft it will pop and make noise in all gears except 5th as it's the 1 to 1 ratio.
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