Reply to "Used ZF found"

Today I took a road trip to look at the used transaxle I ran across. I took all my tools, rags, etc. to take the bottom inspection cover off and I, unfortunately, forgot my camera.

When I removed the oil plug I found some metal pieces on the magnet. The oil smelled fine and was pretty clean but the metal pieces concerned me. I brought home the metal pieces so I could take photos of them (attached). Are these possibly synchro teeth?

When I took the bottom inspection cover off I found that the pinion teeth were chipped at the closet point where it sticks through the housing (see attached photo- I’ve circled the area where they were chipped – this is not a photo of the actual pinion).

I was very careful removing the cover and made sure not to loose any of the shims/washers off the long tensions bolts that go through the bottom inspection cover. I, however, found a small shim/washer that looks like one of the tension bolt shims/washers in the case (I possible could have dropped it in there – but I don’t think so since I was so careful). I also found a few more metal pieces.

The teeth on the ring gear looked good as did the rest of gears on the pinion (except were they are chipped near the housing). These chips appear to be very minor but still a concern. The gears also did not appear to have any rust, etc. Also there was no safety wiring on the ring gear.

I turned the shaft around numerous times and did not see where these chipped areas on the pinion would have ever even come from. The area of the pinion teeth that is chipped is not even close to touching any area of the ring gear teeth. Also the metal pieces on the drain plug appear bigger than the pieces chipped off the pinion gear.

I started wondering if the previous owner had dropped the small shim/washer in the case when he removed the bottom inspection plate in the past, ran the unit, and maybe it ground around in there. However, the pieces of metal on the drain plug could have potentially caused the damage. I did notice the bottom inspection plate had a cork gasket that looked homemade, making me think it had been opened before.

I tried to turn the main shaft and shift gears in the unit but could not. I noticed that reverse light switch was missing and that there appeared to be a rag inside the hole. I unbolted the selector cover and did find a rag stuffed inside and noticed the housing was jammed plum full of grease. This grease was similar to wheel bearing grease. Is this normal? With the selector cover off I could then shift the unit into a few gears but I don’t think I could get through them all.

I am looking for guidance or advice on purchasing this as a spare (possible future rebuild) or for parts. My transaxle case has had an area welded where it was previously cracked and I thought this may be an opportunity to get a replacement case.

I know this transaxle is not worth as much as I originally thought but now am not sure what price to look at. I am also looking for any other ideas on why the pinion gear would be chipped in that area. Any and all your help and advice is much appreciated as always. Thanks and sorry for being so long winded.