ZF5 Transmission Rebuild Part 1 - Disassembly. Project Brutus, Episode 12! 

Out of every video this was the most straight forward way to approach this transmission single handed and without too many of the special tools. This understanding is what a DIY person is looking for. Thank you for your videos. I am sad to not see more on Brutus. I have a truck very similar.

Not a transmission expert here but from what I could see of the disassembly things looked clean and tight. I'm glad you found one that wasn't cracked!

Awesome video, thanks! The machined surface on the concrete drives my OCD into overdrive! lol

These videos are awesome. I am in the process of swapping the C6/BW1345/D44HD TTB out of my 1986 F250, and swapping in a Zf5/BW1356PTO/KPD60 in from my 1988 F350. Since the F250 is a restoration project, these videos are great as far as a how to, with torque specs, and great information. I’ll definitely be sending these videos to people as they need them. Great production, camera angles, and of course mechanical knowledge!

Fantastic work Scott! You did a great job showing a step by step detailed disassembly, but also info between the S5-42 and S5-47 is very helpful info too. Once again you’ve shown that using the right tool for the job not only makes life easier, but also makes a project like yours not too overwhelming. Looking forward to the next video. Take care👍

I’ve been waiting!! I look at your channel 2 days ago and was sad because I didn’t see a new video. I’m definitely happy again!

You're a total badass.

Love your transmission rebuild videos. I have a ZF S5-42 that I will be rebuilding myself thanks to you giving me confidence I can do it! Also appreciate you not swearing on these videos, and you keep your cool! Its fun watching you work through problems.

Great video! I always appreciate your uploads. I am also looking to do a zf5 swap on my truck, and this Brutus series has been excellent! Keep up the good work can't wait until your channel winds up blowing up; I can see it on the horizon.

I am watching this tutorial as I disassemble mine. Thankyou sir

thank you for showing your frustration with 2nd gear, now dealing with the same situation not much to grab and its on tight!

Scott, really am enjoying this series you have created building Brutus! Keep up the good work and the great content. Already looking forward to your next episode!

Thanks for making this video. I just destroyed my ZF5 behind my turbo EFI460 truck at 18psi of boost which put down 840whp and 1200wtq. I knew I was pushing my luck but it lasted a long time.

Great video! I put a ZF5 into my '85 Bronco about 4 years ago, and attempted to rebuild the transmission myself. However, after taking the gearsets out, I couldn't get enough information on how to properly do it and get the gears pulled off, so I took the parts to a transmission shop and had them rebuild it. If I had had your detailed video, I definitely would have done the task myself!

Great instructional video! Thanks for sharing! Merry Christmas! 👍👍👍👍🇺🇸🇺🇸🇺🇸🇺🇸🙏🙏🙏🙏

This was incredibly helpful. Thank you!

Great vid Scott!

Great upload!

Hey Scott, you definitely have a way with making videos. Not only the knowledge you have but also the way you get right down to it, no BS, yet you also keep it interesting. I feel like you would be a great shop teacher. On a side note, do you still have the PTO and pump? I need a PTO and pump for ZF5-47 I’m putting in my 97 F350.

Fox runs across the background in the upper left by the woodpile at 1:08. 🙂

Note to all… be careful about using pullers on the gear faces. Don’t pull on the fine tooth ring. Those are the engagement teeth and aren’t intended to be pulled on. They can be damaged easily. Find another way.

Nice detailed video Scott. I need your toolset!

Do you have any recommendations for getting a rebuild kit, clutch, and dmf or smf? I have heard good things about the Luk and Southbend smf and clutch’s but no experience with them. Thank you so much for the video either way, I think I’ll be able to handle the job and finally justify buying an impact 🫡🙏🏼

Hello! Help me figure out the calculation of revolutions on the power take-off gear. Gearbox ZF s5-42 (5.72). In order to choose the right KOM and hydraulic pump, I need to know the number of revolutions that the power take-off gear makes. It is located on the intermediate shaft. It has 45 teeth on a gear ratio of 5.72 and 43 teeth on a gear ratio of 4.65. Do I understand correctly that it engages with the primary shaft, with that part of it on which there are 27 teeth on the gear ratio 5.72 and 29 teeth on the gear ratio 4.65? Then at 1000 revolutions of the motor it will have 600 revolutions at the gear ratio of 5.72 and 670 revolutions at the gear ratio of 4.65? or not? Thanks!

Very instructive. One problem, cannot find rebuild/ reassembly video. Why not? I am halfway through my project and now what? Help me out.

Great video, I have an e40d in my 7.3 idi f250 that needs to be rebuilt. I'm not blessed enough to have the zf5 or the money to swap it. Just out of curiosity what is it you plan to tow with your truck? I only have a 3000 lb boat to tow and the occasional lawn tractor or truck bed of mulch for the gardens so my transmission is gonna live an easy life lol.

Am I the only one who seen the fox at 1:17?

Nice work! When is the reassembly video coming?

Hey! Im doing a rebuild as we speak on one of these. Im in a time crunch and have been trying to figure out acquiring shims for the preload. All my local transmission shops dont have any and when i inquire about potential diff carrier or pinion shims for a substitute, im left with more questions than answers. Ive seen legend of such a thing but cant find dimensions on the diff shims. Have you found any leads on this issue, or even have this issue? If all else fails i may just make some custom shims out of sheet metal or soda cans or order some that are close enough from mcmaster-carr. Thanks in advance!

I kinda hate my zf5. Shifts like a truck trans. Have to match the rpms to the speed.