2 Big Broncos Forums
John Carder
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• Boulder, CO, USA |
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• Registered on 11/22/2003 |
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• 3 posts |
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 Posted:11/23/2003 00:25 |
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Hi all,
I've had a problem with my 1994 Bronco's 5-speed overdrive manual transmission (ZF-S547). The dealer repaired it, but I'm having the same problem again. It involves the 2 to 3 shift. It's as if the transmission avoids the synchros unless you are extremely careful in moving the stick. Considering that this is the third big Bronco I've owned with this transmission, and the only one to act this way, I thought I'd see if anyone had any suggestions.
I figure the clutch is nearing its end of life (70k miles on the Bronco), so I'll probably have a local shop pull the tranny anyway. Any suggestions for beefing it up or for a beefier 5-speed?
I've owned five "big" Broncos since 1984, all of them bought new, and all of them with a stick (manual transmission). Obviously, I love them. Because I can't stand an Expedition or Excursion, even if they were available with a stick (they are not!), I want to keep my Bronco going as long and strong as possible.
I've lived on an 8,300' mountain in CO for almost 19 years. It's at the top of a 4.5 mile road that averages a 9.7% grade. The 5.0L/5-Sp combo has proven superb for these extreme conditions, but there's something weird about this one. Should I be looking for a rebuilt tranny? Should I check the 5-speeds available for the 250/350 pickups? I'm sure it doesn't make economic sense, but I love the short wheel base with wide track of the big Bronco. We average 220" of snow a winter, and this is my 19th winter plowing snow on my 0.7 mile dirt driveway (not with the Bronco). That means I'm more comfortable going sideways than straight ahead. The Bronco is just plain tossable with that short wheel base, and I love it. I run 31" tires, but would never consider lifting it. While my driveway is more off road than many SUVs ever see, I prefer to keep the COG low, so that it can hustle around the hairpins. The only mods I've made are to replace the rubber bushings with graphite impregnated polyurethane (Energy Suspension, a superb upgrade if you like to drive hard), replace the shocks and replace the cat & muffler with a cat back and V-Force free flowing system. I'm a volunteer fireman, so love the "Project Responder" idea. |
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Bob Kennedy
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• Olympia, WA, USA |
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• Registered on 9/19/2001 |
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• 93 posts |
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Posted:11/23/2003 13:20 |
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Are you sure it's the ZF model and not the M5OD? Either way, a 2 to 3 shift changes shift rails as you go up and over. I'd bet that the shifter fork is bent. It's catching the 1st gear path as well as the 3rd when you go up.
The fact you have kept your rig pretty much stock, I'd go with fixing the gearbox, or replacing it with the same.
Bob K.
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John Carder
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• Boulder, CO, USA |
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• Registered on 11/22/2003 |
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• 3 posts |
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Posted:11/23/2003 16:52 |
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Thanks for the quick reply!
[/quote] Are you sure it's the ZF model and not the M5OD?[/quote]
I'm pretty sure, but I'll double-check. I believe the ZF has the cross-hatch webbing on the outside.
[/quote] I'd bet that the shifter fork is bent. It's catching the 1st gear path as well as the 3rd when you go up. [/quote]
That sounds right, but the fact that it happened again so quickly makes me wonder whether something else is allowing it to be bent more easily. This is my third big Bronco with that setup (5.0L/5sp), and the first to ever do it, so doing it twice raises my suspicion .
[/quote] The fact you have kept your rig pretty much stock, I'd go with fixing the gearbox, or replacing it with the same. [/quote]
I could see going with a Kenne Bell supercharger, if I thought the driveline could handle it. I'll probably take the shop's advice (recommended by a mechanic I trust, who stays away from transmission work).
My question was mostly regarding experience with the other transmissions that might fit. I love the ratios in mine. I've got the old 4-sp (granny + 3) in my plow truck ('86 F26HD supercab w/460), and while it's strong as an ox, the range of ratios is limited and it shifts like a truck (disengage, select, wait and engage). I had noticed that Ford was putting 5sp sticks on their new HD pickups and have no idea what they're like. If it's similar to what I've got, but stronger, I'm definitely interested. I've got less than 70k on the Bronco. I do drive very hard, but maintain it religiously. I do want to keep 'er going. I don't mind if she goes a bit quicker .
jc
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