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Okay, I have the transmission back in now. It was the clutch fork that broke. I replaced it with the OEM upgraded fork from the 2001-2003 7.3. I also welded in a fill plate in the factory stamped hole and stitch welded two steel rods under the rib folds. It's very solid now, even tried bending...

Well, after several months of running my rebuilt ZF6, it's still good and I'm happy with it. The solid bronze bearing has given me no trouble, along with the modified pedal tree. However, one fly in the ointment is the throwout bearing arm. It looks like it's bent, because I measured the...

HAHAHA that's funny.

Try disconnecting the start switch wire from the solenoid mounted on your right hand fender first. This will indicate which direction your problem needs to be chased. Generally speaking: One direction: Start Solenoid>Harness>Starter Solenoid/Plunger>Starter (2001 uses the start solenoid on...

I can't tell you for sure without actually seeing the condition of the clutch, clutch hydraulics, or the guts in the transmission. Obviously you can't get a reliable diagnosis from a Doctor over the Internet for a complicated medical problem like brain cancer and the same rule applies with...

"I made a simple post with a few interesting observations on the Bridge that you referenced as a product endorsement..." My goodness. Didn't Mommy hug you lately? Lose your fuzzy wuzzy Teddy Bear pookie pups? Been watching way too many commercials and can't sleep because the NORK's have...

The Cali Commies in Sacramento can do anything they want. Or didn't you notice that? Secondly, the painting routine for that bridge is when they finish one side, they start back on the other. Obviously you haven't considered the way Unions work hand in hand with 'gubmint' contracts, have you...

About Glyptal Glyptal is the preferred insulator paint for high voltage transformer cases by your local power company. It’s some of the very toughest insulator paint you can buy. If you want it, you’ll have to pay extra Haz-Mat shipping charges ($27.50) to get it shipped to you. And for...

I just use Mercon 5. That's what the trans was designed for, and since I don't have millions to do detailed research on viscosity, contaminants, thermal-dynamic flow characteristics, particulate suspension properties, i'll just trust those guys. :drool:

Hi Byron, If it's all the time it sounds like you may have some slop in your bearing preload. Another cause can be a ****ty pilot bearing. If that pilot bearing is the needle bearing roller style, my money is on that. I have tossed the needle bearing roller style in my 7.3 with an old skool...

Very nice. They aren't all that bad if you take your time. Once you do a ZF6, a ZF5 is child's play. Just make sure you have that synchro ring chamfer installed correctly on that back half. those are specific as to the direction the chamfer points. The manual points this out. I'll bet the...

Sounds good, will do. As soon as i get some material together, I'll get on it. Thanks for the suggestion. :D

BTW- I like ZF5's. They get the job done and are much easier (and cheaper) to rebuild than the ZF6. If I had one around, that's exactly what I would have installed instead of the ZF6, but with a single disk, not those expensive dual disk setups. Besides, who the hell needs the ZF6 creeper...

Yeah, you can do that with a lot of different starters. Bigger stuff like MT40-42's on medium diesels is very common to swap or spin the nose. On those starters, mostly the nose is changed, the rest is the same. But I'm not into the weird jacked up piggyback type of race starters for diesels...

"But this isn't 1980 anymore. Lol" Sent from my SM-G892A using Tapatalk Whuaaaa? Not 1980 anymore? Yeah, thank God for that. I was making $6.50 an hour, and only the worst President EVER was in office, inflation raging 12-14%, Gold was $800 an ounce, interest rates on homes was 18%...

Starter took a dump Wow. My luck lately hasn't been so good. Blasted starter simply rolled over and stuck its legs in the air. I've been reading about numerous complaints in regard to the aftermarket replacement starters- no thanks. Utter waste of good money. So here we go again. I will...

Yeah, I'm in Reno. But I do all my own work so I really don't know a commercial outfit that does that. Generally speaking, if I were to own a 6.0 myself, it would be me, myself and I that would be doing the wrenching. But that's because I hang onto my dollars like a Police K9 on a meth-head...

My vote is bulletproofing it. Fix the design flaws and it'll run a good long time. Those so called extended warranties are usually crap unless sold by a Ford Dealer, and even those are sometimes maddening.

Welcome aboard. Just ask your question, someone will respond. I'm in Reno too. Got an early 99 7.3, 2wd ZF6. Have fun!

They all have a starter relay/solenoid, regardless of what it's on. Earlier (01 and back) 7.3 setups have an additional starter relay mount on the passenger fender, but it too feeds another starter relay that rides within the solenoid switch. In 02, they moved the starter relay from the fender...