[DeTomaso] Another ZF issue

[Thomas Borcich]

John, you were right on. The shift linkage was hitting the u-joint/half shaft.  The previous owner replaced the half shafts and u-joints with heavy duty units and they are evidently much larger than stock. The shift linkage was intentionally bent/modified to give clearance to the half shaft where it holds the u-joints. My guess is that when the engine and trans were reinstalled after the rebuild, the shift linkage was put in slightly different and rotated just enough so that in 5th gear the linkage hits the u-joint when it rotates.

John I owe you dinner. 

Best regards,

Tom Borcich

  ----- Original Message ----- 
  From: John Taphorn<mailto:jtaphorn at kingwoodcable.com> 
  To: Thomas Borcich<mailto:Tborcich at msn.com> ; detomaso at realbig.com<mailto:detomaso at realbig.com> 
  Sent: Thursday, August 24, 2006 4:26 PM
  Subject: Re: [DeTomaso] Another ZF issue


  Thomas

  My batting average on correctly guessing ailments has been horrible; yet, 
  I'll take another swing.

  It sounds as if your shifter shaft is being struck by the portion of the 
  halfshaft that houses your u-joint. Perhaps the bow in you shifter shaft 
  removes what tiny clearance exists when rotated into 5th.

  The correction is to raise the height of the trunion bearing and you will 
  gain more clearance.

  Don't sweat the ZF, it is very unlikely the problem is internal.

  JT
  ----- Original Message ----- 
  From: "Thomas Borcich" <Tborcich at msn.com<mailto:Tborcich at msn.com>>
  To: <detomaso at realbig.com<mailto:detomaso at realbig.com>>
  Sent: Thursday, August 24, 2006 3:13 PM
  Subject: [DeTomaso] Another ZF issue


  > OK, I guess I'm not the only one with quirky problems with the ZF. 
  > Hopefully my issue is related to shifter adjustment.  Just purchased 
  > #4382, a 72L with 27,500 miles on it.  It has the "-2 gear box" and has 
  > not been driven in 10 years, only to and from the mechanics shop who 
  > rebuilt the motor which accounts for less than 10 miles and never reached 
  > any speeds appropriate for 5th gear during the drive home. Prior to that 
  > no problems with the gear box.  I tried to shift into 5th gear over the 
  > weekend and I got a clunking noise that pushes back into the shifter 
  > handle...it is a consistent clunking noise that moves the shifter handle. 
  > It appears that I get 5th gear and can hear the motor drop rpm's, but the 
  > clunking sound continues and forces you to pull it out of gear for fear of 
  > doing damage to the ZF.  I have drained the gear oil and refilled and 
  > found no chunks of metal, actually pretty clean. All other gears shift and 
  > operate well. I did notice that there is a slight bend in !
  > the linkage which gives the linkage a bow, so I need to replace a short 
  > length of the linkage to cure that issue. Any thoughts or similar issues?
  >
  > I spoke to Mad Dog Antenucci who mentioned the trunion bearing/support may 
  > need replacing, (just as a normal part of maintenance if nothing else). I 
  > have been told that you can replace it with a metal Hiem joint affair 
  > rather than the rubber bushing and you get a more direct feel from the 
  > shifter linkage, any comments?
  >
  > Thanks in advance for any suggestions
  >
  > Best regards,
  >
  > Tom Borcich
  > Seal Beach, CA
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