This video shows the problem that suddenly developed with my ZF-2. It only has about 500 miles on it since a total overhaul, and up till now has worked fine.
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Maybe try overfilling it with lube and roll it over once or twice on the bench. Something could be dry.
I agree the MJ. Don;t take it apart until you have tried the items he suggested above. The trans wont shift static unless the input shaft is turning. Try it.
Mine will shift with engine off also
As will mine. Has been that way for 35 years.
The video shows that he cannot shift into second or third gears, AND the shift shaft cannot be rotated to the 4 / 5 "slot".
John
Got it. But earlier in this thread someone said that testing it on the bench like that would not be a good test unless there was rotation of the input shaft and output flanges.
obviously an incorrect statement
Larry
If it developed a problem in 500 miles, then clearly something has gone wrong. I have multiple ZF's here out of the car and can shift every one through the gears. If rebuilt by a vendor I'd ship it back to them for repair.
OK - let me clarify a few things. My problem originally happened while I was driving. I was stopped at a light, and when I clutched and went to put it in gear to go - no go. I struggled with it a few seconds and finally managed to get it in 5th, lugged it ahead until I could clear traffic and get it off to the side of the road.
Later when I was inspecting things, I found no fault with the clutch, but I did find the shift shaft support bushing slightly loose. This may have contributed to the problem, but I can't say that with certainty yet. I tightened it up, re-aligned the shift linkage, jacked the rear end up, started it, and tried shifting gears - still no go. I will post again when I find something definitive.
I decided to work on it myself - or at least attempt to - simply due to the cost of shipping. It has tripled since I first had the transaxle done in 2019.
So a fully functional ZF becomes seriously compromised with no prior issues or advanced warning.
something came loose. Somewhere
at the bottom of the selector housing, the box on the drivers side of the ZF, are two rubber plugs that provide access to the set screws on the selector arm. From the video I don’t think that is your problem but it is worth checking
Also worth checking - on the passenger side of the ZF is a small 1“ x 2“ flat plate held on with two bolts. Removal of that plate will provide access to the two set screws on one of the shifter forks. That cover does have a paper gasket so carefully remove or plan on replacing.
Those two checks can be done without opening the ZF case. At least worth a look.
Larry
Also check the speedo drive, if that breaks then then end drops into the transaxle.
Shipping is certainly more expensive than it was, but I shipped two transaxles a couple months ago (Reno, NV to MD via YRC Freight) for $210 ea. If it's potentially a warranty issue then I'd be shipping it to your rebuilder.