ZF 5 Second gear dosent work?

[COSCAG00]

Well I finally have my 4bt in and running but now my transmission is acting up. It shifts great through all the gears but second gear. After doing some reading it looks like the synchro for second is out. I think I will have the transmission rebuilt. What all do I need to have done? The bearings seem good and everything else functions great. So do I at a minimum replace all bearings and synchros? Is there anything else to replace while I have it pulled? Can I get away with just replacing the synchro for second?

 

[sykanr0ng]

I have not rebuilt one myself.
But looking into it for future need it seems not too hard for someone with enough skill to swap a diesel into a Bronco.

Here is one forum thread with instructions, it is the later type S5-47, but for the most part they are the same, it is sizes of some components, a refinement not a totally different transmission design:

http://www.fullsizebronco.com/forum/showthread.php?t=216470


Several other threads about it, but some no longer have the pictures that make it so much easier to understand.

I would replace all the syncros at the time, it would be my luck another one would go bad a month after if I didn't.

 

[JB Fab]

I have not rebuilt one myself.
But looking into it for future need it seems not too hard for someone with enough skill to swap a diesel into a Bronco.

Here is one forum thread with instructions, it is the later type S5-47, but for the most part they are the same, it is sizes of some components, a refinement not a totally different transmission design:

http://www.fullsizebronco.com/forum/showthread.php?t=216470


Several other threads about it, but some no longer have the pictures that make it so much easier to understand.

I would replace all the syncros at the time, it would be my luck another one would go bad a month after if I didn't.

Yeah, 2X on that, been there.......

Can you shift it into 2nd with out the engine running?
I have the service manual if you need it?

 

[COSCAG00]

It will go into second but does not like it with the engine running. With the engine off it will go in but its hard. I have to hold the shifter down to get it to fully stay in. Found a local place that will rebuild it, and I think I am leaning that direction.

 

[Hozr]

The ZF is a weird transmission to rebuild, not your average manual. I had it done by a shop as it requires some special tools to assemble correctly.