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Old 10/03/11, 05:11 PM   #1
skifast
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Sandhills, NC
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ZF rebuild

Anyone rebuilt their ZF transmission?

In neutral it makes a terrible rattling sound. It did not do this on initial startup after the replacement. Starts fine, shifts well but, just makes a racket.

Can anyone else take a stab at what I might have going on?

74 Bronco -EFI, ZF, Cage Arms, modified Bailie Bilt front and rear bumpers, 3.5" lift, Bilstein 7100 and 5150 shocks, BFG KM2 35's

1968 U14 going to become the wife's LUBER
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Old 10/03/11, 05:44 PM   #2
nik
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Didn't rebuild mine, but mine makes the same racket in neutral like there's a marble bouncing around. From what I've heard this is fairly common for the ZF.

1969, rebuilt 302, ZF5/np205(twinsticked), 4.88s, Full Widths HP44(locked) & 9"(locked), 4.5 Suspension lift, custom arms, 1" BL, 35s, 1 ton steering w/4x4x2 box custom bumpers & cage, warn bellevue winch, York on-board air etc
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Old 10/03/11, 06:11 PM   #3
Bronco Brian
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Ukiah
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Throwout bearing ??? That's what mine sound like

Quote:
Originally Posted by Wyflyer View Post
I bet you could pull a kitten through the axle tube with a rope and it would act much like swabbing your shotgun barrel with patches...
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Old 10/03/11, 06:26 PM   #4
Apogee
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Input shaft bearing? My NV4500 started making a similar sound before I pulled it and that's what it looks like, but I have yet to tear it all down and rule everything else out.

Did you know that 95% of all statistics are made up on the spot?
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Old 10/03/11, 06:57 PM   #5
siderbox
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Neutral rattle is a fairly common noise in a manual trans.
I'll back that up with 15 plus years as a tech.
Now with that said there are possibly for repairable noises, like the ones Apogee and BB have stated.
Do you know anyone else with a ZF?
Or someone else that you value there opinion close to ya?

Light travels faster than sound. That's why some people appear bright until you hear them speak.
66 HalfCab
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Old 10/03/11, 07:07 PM   #6
hmh800
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I've got one that could shift 3-4 better, and it vibrates a bit in 4th. I've been searching the web for writeups. There's a couple out there, if I can find the link I'll post it up. The rebuild kits seem to cost $350+, depending on what parts you need. Syncros seem like a weak link on high milers. I can't decide after reading what I've seen if it's something I want to tackle. I did my own R&P, and transfer case, but there's a lot more parts in a ZF. Let me look for those links...
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Old 10/03/11, 07:10 PM   #7
hmh800
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Here's one:

http://www.ford-trucks.com/forums/58...ifficulty.html
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Old 10/03/11, 07:25 PM   #8
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My ZF does the same thing and everyone said it if pretty common.

68 3.5" lift 5.0L 4R70W/Klune V/D20, 4.88, 35s, ARBs

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Old 10/03/11, 07:29 PM   #9
bigmuddy
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They call it neutral rollover noise. Same reason that Ford did a recall and fixed it by sticking some heavy padding between the carpet and the tranny tunnel. My seems to be worse after driving all weekend in low low around the 4x4 park. Normally it's just mildly aggravating but I try to not let my bronco idle much.

Ben

75 EB, 35" tires, EFI 5.0 with Explorer stuff. ARB/ Aussie locker, ZF tranny, 4.56 gears, twin stick, 2.5 BC lift, Cage long arms and dual shock kit,Ghetto fab hydroboost with disc brakes,yada,yada,yada!
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Old 10/03/11, 07:52 PM   #10
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Mine sounds like it's got gravel in it while in neutral... It's been installed for about 4 years.. The ZF came from my paw-n-laws well used farm truck. All I have done to it is changed the fluid.

ZF Trans, Atlas Transfer, P/S, 9.00x16 CO-OP Grip Spurs or 37 Pit Bulls, Hydro brakes, 3.5" lift , 4.56 locked F/R with longarms, MM10500 hyd winch, EFI!!
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Old 10/03/11, 08:21 PM   #11
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Yup mine makes a bunch of noise in neutral. Same thing with the one I put in my f250 as well.

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Old 10/03/11, 09:56 PM   #12
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I use to have a 96 250 with the ZF and it made the rattle sound when in nuetral pretty much from new till I sold it with 150,000 miles never a bit of trouble with it.

75 EB, 96 351W, ZF Tranny, 4:11 gears, Twin Sticks, 2.5" WH lift, 1" body lift, Dual Shocks, Explorer Serpintine Belt, 33x12.5" BFG, 750 Quadrajet, painless harness, ARB rear locker to be continued.
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Old 10/04/11, 04:36 AM   #13
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When I first installed it, there was a whirring sound. New input bearing, new clutch assembly, BC ZF install kit and junkyard 89 F-250 ZF S42, just the back story.

It sat for two months while I was doing body and cage work. Started it and now all the racket it is loud like the transmission is tearing itself apart. The wife even asked if there was something wrong with the Bronco. Although still seems to shift fine.

It seems all my co-workers are a new car crowd and not alot of older F-250's running around to compare the sound of their ZF noise.

A long time ago I drove an Army buddies truck with the ZF and you could hear the transmission but, it was nothing like this. Or so I remember.

I have the Haynes manual for the year model F-250 I pulled the trans from and it said " noisy in neutral engine running" Input shaft bearing worn, damaged main drive gear bearing, worn countershaft bearings, or worn or damaged countershaft endplay shims.

I hear the folks say just run it but, I think the noise it is making is a little more than transmission noise, maybe?

In the end I am not a mechanic and have made it through all of my Bronco repairs by reading the book on the fender as I am doing it.

So run it or rebuild it, I guess I could just pad the heck out of the trans tunnel and wear ear plugs!

74 Bronco -EFI, ZF, Cage Arms, modified Bailie Bilt front and rear bumpers, 3.5" lift, Bilstein 7100 and 5150 shocks, BFG KM2 35's

1968 U14 going to become the wife's LUBER
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Old 10/04/11, 07:13 AM   #14
bigmuddy
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I hate to admit this, but right after I installed my ZF I forgot to add fluid and let it idle like that for about 30 min in neutral. Fluid for the tranny didn't make the punch list for start up for some reason? It made one helluva a racket and sounded like rocks in the tranny. I realize that the ZF takes a synthetic tranny lube but I have been succesful in adding a pint of lucas oil to the tranny to get it to be a bit quieter. Not saying you should do it, but it worked for me.

75 EB, 35" tires, EFI 5.0 with Explorer stuff. ARB/ Aussie locker, ZF tranny, 4.56 gears, twin stick, 2.5 BC lift, Cage long arms and dual shock kit,Ghetto fab hydroboost with disc brakes,yada,yada,yada!
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Old 10/04/11, 08:01 AM   #15
KyleQ
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It's very common for people to add a bit of extra fluid to quiet it down. Another thing to consider is that our Bronco's are like one big resonating speaker, that same transmission in a newer pickup with it's curvy steel with foam and carpet over it makes a big difference.

I would just add at least a quart of fluid to help quiet it down - the guys on OilBurners will even damn near fill it up and they are pulling heavy loads with them...

74' Bronco - Mustang EFI 5.8 w/Explorer Serp - NP435 - AtlasII 3.8 - D60/D70 - PSC Full Hydro - 5.5" lift - Cage Arms, Coils and Shocks - F-O-A 2.5" Air Bumps - 43" TSL SX on H1 Double Beadlocks

74' Bronco Ranger - Street Build in Progress (351W/NP435/NP205)
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