S5-42 Manual Trans 1992-1995 F-series 7.3L, 5 Speed, PTO Not In Use

Description

Prevent gear pop-out under 420 lb-ft sustained diesel torque while maintaining low internal lubricant temperatures across demanding high-mileage regional heavy hauling routes using the ZF S5-42 Remanufactured Manual Transmission engineered for 1992 to 1995 Ford F-Series heavy work trucks equipped with the 7.3-liter diesel engine without auxiliary PTO requirements.

One-piece cast aluminum casings provide high strength while eliminating leaks across split-case joints. Multi-cone synchronizers on second and third gears feature carbon-composite linings that resist burn under loaded downshifts. A heavy 6-bolt cast block-off cover seals the side PTO window against lubricant leaks. The transmission weighs 175 lbs dry without lubricant. Sump capacity requires 3.4 quarts of synthetic Mercon ATF fluid routed through magnetic fill and drain bungs.

Key Features of ZF S5-42

Commercial fleet managers choose to buy ZF S5-42 remanufactured transmission units to eliminate gear hop and bearing squeal in dedicated highway freight trucks. Every rebuilt core receives brand new synchronizer rings, bearings, and seals to provide trouble-free manual shifting.

• Sealed 6-bolt PTO block-off plate prevents gear oil leaks on non-PTO fleet trucks.
• Carbon-composite synchronizers prevent gear grinding during heavy trailer hauling.
• Precision ground helical gears handle 420 lb-ft continuous input diesel torque.
• Hardened shift rails and detent springs stop transmission jumping out of gear.
• High-grade tapered roller bearings maintain mainshaft endplay within factory tolerances.
• Integrated aluminum bell housing bolts flush to Ford diesel engine intermediate plates.
• Remanufactured ZF S5-42 gearsets undergo spin checks to guarantee silent gear mesh.
• Viton input and output shaft seals withstand continuous 250°F operating spikes.

Diesel Reduction Ratios Torque Limits

The 5-speed manual gear set provides close ratios featuring 4.14:1 in first, 2.37:1 in second, 1.42:1 in third, 1.00:1 in fourth, and 0.77:1 in fifth gear overdrive. Continuous duty designation supports up to 420 lb-ft continuous input torque at 2,000 RPM. Large helical gear tooth profiles divide driveline load forces across wider tooth contact surfaces. External casing cooling fins dissipate operating heat to maintain lubricant sump temperatures below 180°F under maximum gross combined vehicle weights.

Shaft Spline Centerline Alignment Specifications

A 10-spline 1.25-inch diameter input shaft seats into standard diesel clutch discs with zero spline bind. The rear output shaft links straight to chassis driveshafts with dial indicator runout held below 0.002 inches. Heavy-duty rear extension housing bearings support driveshaft weight without deflection or premature seal failure.

Manual Transmission Operational Service Standards

Check clutch hydraulic master and slave cylinder travel to ensure complete disengagement before initial road testing. Fill the transmission case using synthetic Mercon ATF fluid through the side inspection port. This unit is not engineered for closed-course drag strip racing, extreme rock crawling, or gross combined vehicle weights exceeding factory chassis tow limits.

• Inspect front quill tube and rear extension housing for fluid leaks each shift.
• Drain transmission fluid, clean magnetic plugs, and refill every 30,000 miles.
• Check manual transmission mount bushings and crossmember bolts every 12 months.

Commercial Crate Manifest Warranty Policy

Protected by an industry-leading 3-Year / 100,000-Mile commercial fleet warranty covering certified parts and labor. Each heavy wooden shipping crate contains one complete remanufactured manual transmission, sealed PTO block-off plate, new throwout bearing, chassis installation manual, and signed rotational inspection report.