Reply to "ZF crack question"

If you want to play with the assembly, fine. Not only will you learn about the assembly but if it needs shipping for welding, every part removed lightens the shipping weight. You will need very high quality metric allen wrenches for this work, and a copy of the ZF Overhaul Manual. POCA sells them in their manual collection as well as some vendors. Take lots of photos as the work progresses. Time WILL pass while the work goes on and you WILL forget details during reassembly.

Remove the ZF from the car, then remove the bellhousing and lower cover. Remove the iron side covers. Remove the transmission case allen bolts. There are numerous internal ribs and divider bulkheads inside that prevents full draining, so be prepared for a mess on the floor! These things also catch & hold debris so you may find a surprise or two.

The tranny case likely won't separate from the diff case even with the bolts out, unless you lift the whole assembly and while holding the diff case vertically, bump the protruding clutch-input shaft hard against a thick piece of wood. There is no gasket but there may be some contact cement. The final part to take off is the iron end-plate. In all the removed sections, there are shims that will need to be put back exactly.

You will likely break a few metric allen bolts in stripping the assembly; ZF used very tight reduced-head bolts and the allen hexes often strip out. Seals are generic but some bearings are not. RBT sells all needed parts. Also do not skimp on gaskets- the gasket's thickness controls some gear mesh depths, so use real ZF parts. Gaskets, bearings and seals are the only cheap parts in there! Good luck, and if at any time you feel in-over-your-head, the vendors are there for you.