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assembly. 07-03B-1. 1994 Econoline / F-150, F-250, F-350 / Bronco / F-Super Duty Powertrain, Drivertrain Aug 1993. Page 2. TRANSMISSION ZF S5-42 TRANSMISSION ZF S5 42 TROUBLESHOOTING GUIDE SERVICE TIPS ZF Industries DESCRIPTION AND OPERATION Description The model number for the ZF transmission 7003 is S5 42 This model number can be divided into three parts First S designates a synchronized transmission Second 5 designates the number of forward gears Finally 42 is the approximate maximum input torque capacity in tens of ft lb In this case 42 equals 420 ft lb input torque capacity The S5 42 ZF transmission is available in both wide ratio and close ratio versions The wide ratio version is available for all F Series vehicles over 8500 lbs GVW all engines 6007 except F Super Duty Commercial Stripped Chassis equipped with a diesel engine The close ratio version is available only in F Series vehicles with a 7 3L diesel engine and a GVW over 8500 lbs The ratios are as follow 1st 4 14 5 72 2nd 2 37 2 94 3rd 1 42 1 61 4th 1 0 1 0 5th 0 77 0 76 Reverse 3 79 5 24 Close Ratio Diesel Wide Ratio Gasoline Diesel The transmission features an aluminum case 7005 with an integral clutch housing Because of the aluminum case the tapered roller bearings of the transmission shafts must be fitted under preload This is because heat expansion of the aluminum case is greater than that of the steel alloy mainshaft and countershaft cluster gear 7113 If the bearings were not pre loaded this would result in excessive end play when the case in warm loaded operating conditions The transmission also features shrink fit gears on the countershaft cluster gear Shrink fit gears are connected to the countershaft cluster gear by friction only rather than connected trough splines The gear is heated and lightly pressed onto the countershaft cluster gear The subsequent cooling of the gear provides the shrink fitting The countershaft cluster gear is serviced as an assembly 07 03B 1 1994 Econoline F 150 F 250 F 350 Bronco F Super Duty Powertrain Drivertrain Aug 1993 TRANSMISSION ZF S5 42 TROUBLESHOOTING GUIDE SERVICE TIPS ZF Industries DIAGNOSIS AND TESTING Inspection and Verification A troubleshooting guide has been put together to assist diagnosing transmission related problems Use the transmission noise evaluation procedure and troubleshooting guides on the following pages or refer to Section 07 00 in the 1994 Ford Service Manual Also refer to Section 08 00 in the 1994 Ford Service Manual Remember it is important to get an accurate description of the complaint before any diagnosis can be performed Ask questions as to whether it occurs hot or cold during shifting driving at a particular speed or in a particular gear If possible have the customer demonstrate the concern Cold Transmission Drive the truck in all gears 1 5 and reverse gears Evaluate the noise in neutral Check if there are any noise changes in a particular gear i e 4th gear In 4th gear the countershaft is not under load Check if the noise increases when the transmission is warming up See if the noise is related to engine speed road speed or gear selection Warm Transmission Check all gears plus reverse gear and make note of any noise changes in a particular gear Check noise in neutral while parked Check if the noise disappears at a certain engine rpm or with the clutch pedal 7519 depressed Drive in the gear in which the noise is most noticeable Press in the clutch and leave the gear engaged If the noise changes or disappears the noise may be amplified by the vibration of the engine Drive under the same condition again Press the clutch pedal in and shift into neutral Release the clutch while the truck is coasting down the road Evaluate the noise as the rear axle assembly 4006 turns the mainshaft 07 03B 2 1994 Econoline F 150 F 250 F 350 Bronco F Super Duty Powertrain Drivertrain Aug 1993 TRANSMISSION ZF S5 42 TROUBLESHOOTING GUIDE SERVICE TIPS ZF Industries DIAGNOSIS AND TESTING ADDITIONAL TESTING FOR 4X4 TRUCKS Non Electronic Shift Check for any noise change when shifting the transfer case 7A195 between 4X2 4 high 4 low or into neutral With the vehicle at a complete stop and the transfer case in neutral shift through all the gears and evaluate noise at different engine rpm Check for any noises in neutral at different engine rpm NOTE To isolate clutch concerns from transmission concerns operate the transmission at no load On 4X4 models place the transfer case in neutral Remove the driveshaft on 4X2 models Run the engine at 3000 rpm and operate the transmission throughout ranges with the clutch engaged If hard shifting concern power to transmission disappears the concern may be in the clutch system An improperly operating clutch can result in hard shifting that is most noticeable in 1st 2nd and reverse The hydraulic release mechanism must work properly Continued operation with a defective clutch system may result in premature wear or damage of synchronizer 7124 Hard shifting or difficulty engaging gears may be the result of improper clutch function Check the release system travel Minimum travel for the concentric slave cylinder bearing 4 9L and 5 8L engines and the external system slave cylinder push rod 7 3L and 7 5L engines is 11 mm 7 16 inch If system travel is less than 11 mm this is an indication of problems in the release system such as excessive flexing of the instrumental panel 04320 cracked instrumental panel reinforcement at the clutch master cylinder mounting and air or water in the hydraulic clutch hose 7T504 Refer to Section 08 00 in the 1994 Ford Service Manual If release system is greater than 11 mm and the clutch is suspected check for clutch reserve as follow 1 Set the parking brake control 2780 and put the transmission in neutral 2 With the clutch pedal fully depressed shift into reverse then shift half way between reverse and neutral to defeat the synchronizer 3 Allow the clutch pedal to fully return and adjust the position of shift control selector lever and housing 7210 to obtain light contact between the gear teeth
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