In this episode, I reassemble the ZF S547 4x4 transmission that I disassembled way back in Episode 12 of Project Brutus! This video covers the entire reassembly process from start to finish, including installing new bearings, synchros, setting the preload by using the correct shims, and all the applicable torque specs.
It took so long for me to get to reassembly because I was trying to source a good extension housing to replace the cracked one that was repaired twice. I ended up finding one back home in Texas for $400, but I had to buy the entire transmission to get it! FYI - the F Super Duty (and maybe the F450 and F550) is a heavy duty truck with 10 lug wheels and in a 2WD version, it uses the 4WD version of the ZF5 because it has a monster parking brake hanging off the back of the transmission. That's where I sourced my extension housing from.
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Thanks!
Scott Walters