Section 07-03B: Transmission, Manual, Model S5-47 ZF
1996 F-Series Vehicles Over 8500 lbs. GVW Workshop Manual
CLEANING AND INSPECTION

Transmission

Cleaning

  1. NOTE: Do not clean, wash or soak transmission seals in cleaning solvent.

    Wash all parts, except seals, in a suitable cleaning solvent. Brush or scrape all foreign matter from the parts. Be careful not to damage any parts with the scraper. Dry all parts with compressed air.

Inspection

  1. Inspect case (7005) for cracks, worn or damaged bores, damaged threads, or any other damage that could affect operation of the transmission (7003). Inspect the machined mating surfaces for burrs, nicks or damage.

Case Service

Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the vent for obstructions, and check all fluid passages for obstructions and leakage.

Inspect the case bushing for scores. Check all parking linkage parts for wear or damage.

If a transmission case thread is damaged, service kits may be purchased from local jobbers. To service a damaged thread, the following procedures should be carefully followed:

  1. Drill out the damaged threads, using the same drill size as the thread outside diameter. For example, use a 5/16-inch drill for a 5/16-18 thread.

  1. Select the proper special tap and tap the drilled hole. The tap is marked for the size of the thread being repaired. Thus, the special tap marked 5/16-18 will not cut the same thread as a standard 5/16-18 tap. It does cut a thread large enough to accommodate the insert, and after the insert is installed, the original thread size (5/16-18) is restored.

  1. Select the proper coil inserting tool. These tools are marked with the thread size being repaired. Place the insert on the tool and adjust the sleeve to the length of the insert being used. Press the insert against the face of the tapped hole. Turn the tool clockwise and wind the insert into the hole until the insert is one-half turn below the face.

  1. Working through the insert, bend the insert tang straight up and down until it breaks off at the notch.

  1. Improperly installed inserts can be removed with the extractor tool. Place the extractor tool in the insert with the blade resting against the top coil one-quarter to one-half turn away from the end of the coil. Tap the tool sharply with a hammer until the blade cuts into the insert. Exert downward pressure on the tool and turn it counterclockwise until the insert is removed.