In this video we will be rebuilding the ZF S5-42 transmission from my truck.

Let me start off by stating that I am not an expert, just a guy in his garage with a rebuild manual. The reason for rebuilding is bearing noise, difficult downshifting from 3rd to 2nd, and "slop" when you let up on the gas. These issues have been mostly fixed, but not fully. These ZFs are known to have some bearing noise, even when new or freshly rebuilt, which explains why there is still some noise present.

I was able to tackle most of this job with common tools, but did have to rent many types of bearing pullers from O'Reilly's and AutoZone. The two tools I ended up buying were an 8" jaw puller from Northern Tool, and an OTC 6542 bearing cup puller.

Information:
Here's the rebuild I saw on the forums - https://www.oilburners.net/threads/zf...
Rebuild manual PDF - http://www.vaglinks.com/Docs/Catalogu...

Parts suppliers:
Midwest Transmission - Synchro slider, slider detent balls
Nogalitos Gear - Shim kit
Allstate Gear - Shifter rebuild kit, output flange nut
eBay - Rebuild kit

Tools used in this video:
Milwaukee Impact Gun: https://amzn.to/2ZlFPPE
Milwaukee Drill: https://amzn.to/2KOTX00
Condiment Bottles: https://amzn.to/33QCkEk
OTC Bearing Cup Puller: https://amzn.to/31Ub5ag
8" Gear Puller: https://amzn.to/2DihOk1
Anaerobic Gasket Maker: https://amzn.to/320Yan7

Disclaimer: The content provided in this video is for informational use only. Video content is provided at the viewers own risk and the viewer will not hold the parties involved in creating, producing or delivering this information liable for any loss, injury, claim, liability, or damage of any kind resulting in any way from any errors in or omissions from the information. Thanks for understanding.