Problem with ZF-5 and BC Broncos

Post by **pgilbeau** » Sat Jul 01, 2017 8:35 pm

I will try and keep this short as I am at a loss at the moment and pissed to no end. I purchased a rebuilt ZF-5 and cross member from BC Broncos thinking that this would be a better option then finding a used transmission. Everything seemed fine as the build was coming together and then once it was completed and I started driving it I realized there was a leak in the transmission. Upon further inspection the tail housing had been welded and painted over and was leaking. I contacted BC Broncos and they sent out another transmission. Although I wasn't happy about switching the transmission I was happy that I would be getting rid of the leak. Anyway went to the shop today to do the swap and now I don't know what to do. Pulled the trans and Atlas and got them on the ground and realized the transmissions are not the same. The biggest difference is the original ZF-5 I received is 27 and 11/16" vs 29 and 1/4". I started doing some research and found out the original transmission I received is a 2wd ZF-5 converted to 4wd. I am not sure what to do at this point, everything that was fabricated was done based on this shorter transmission. I know for certain that this means the notch in my frame for the Atlas is in the wrong place and my new drive shafts are probably the wrong length. I also think that my shift tunnel that was fabricated is now probably in the wrong place and my new exhaust might be wrong now also. An inch and a half difference is going to throw everything off, I don't even see how BC Broncos can make this right after sending me the first abortion of a transmission. I will be contacting them as soon as they are open. Looking for advice, etc.

Post by **Kinder** » Sun Jul 02, 2017 12:19 pm

Wow, didn't even disclose they were sending you a converted 2wd is wrong. That said, the easy way forward is to have them send you another converted trans. Not ideal, but likely the only solution to getting it back together and driving without all new fab.

Post by **Justin** » Sun Jul 02, 2017 3:20 pm

That's the solution i'd aim for. For them to not catch or disclose that is significant and should be made right.

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Post by **ZOSO** » Sun Jul 02, 2017 4:41 pm

Man that sucks. I will just say good luck with BC broncos

Post by **pgilbeau** » Sun Jul 02, 2017 5:48 pm

Thanks guys! It took me a minute to figure out the difference in the transmissions. I will be calling them as soon as they are open and hoping for the best. I am just not happy at the moment, should be wheeling.

Post by **Eck** » Sun Jul 02, 2017 6:20 pm

Did you already send the old one back? If not, maybe they will pay for you to find someone who can professionally weld it so it won't leak and throw in a gift card for your trouble...

I didn't know BC when Chuck was the one running it, but they seem to be a small fish at this point trying to play in a big pond. Whenever I've called for technical help on something I've bought from them- there only seems to be 1 person that can answer the question. If that means they only have one competent person working for them, it doesn't surprise me of all the bad press they've seem to have gotten the last few years in the Bronco Community. Good luck- the worst part is all the metal that you measured and can't go back and uncut/unnotch.

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Post by **pgilbeau** » Sun Jul 02, 2017 9:35 pm

Eck wrote:Did you already send the old one back? If not, maybe they will pay for you to find someone who can professionally weld it so it won't leak and throw in a gift card for your trouble...

I didn't know BC when Chuck was the one running it, but they seem to be a small fish at this point trying to play in a big pond. Whenever I've called for technical help on something I've bought from them- there only seems to be 1 person that can answer the question. If that means they only have one competent person working for them, it doesn't surprise me of all the bad press they've seem to have gotten the last few years in the Bronco Community. Good luck- the worst part is all the metal that you measured and can't go back and uncut/unnotch.

I actually have both the original and replacement at the moment. I am not sure welding it will be an option, they already tried to weld, grind, and paint over the crack. I feel like to weld it right you would have to pull the tail housing which means everything is coming out of the case. I have noticed the same thing, everything has to be answered by Jason and they don't get back to you very quick either. I actually had another problem there when I tried to order a dash blank, they never said they didn't have it in stock and just held all my items. The problem was when I called the dash was indefinitely back-ordered, wonder how long they would have waited. To be fair I have had some issues with other vendors also but not on this level.

Post by **Jesus_man** » Mon Jul 03, 2017 5:03 am

Sorry to hear of the issues. I too would be asking for a converted tranny of the same length.

As for dealing with BC's - I am sorry to hear that as well. I have spent some time with those guys when they moved their shop to TX. Chuck and the rest of the crew are great people, but it sounds like Jason may be in over his head at the moment?? Start with the honey vs the vinegar approach and I hope you get what you need in the end!

Post by **pgilbeau** » Mon Jul 03, 2017 9:14 am

Called BC Broncos this morning and am now waiting to hear back from them as to a fix. I am going to add some information I learned so that maybe it helps someone in the future. Basically Jason told me when they can't find 4x4 ZF-5's their re-builder uses a 2wd ZF-5 and a diesel tail housing to make a 4x4 transmission. The big difference other than the webbing is the length, the converted trans is 27 and 13/16" while a regular 4x4 ZF-5 is 29.25", the difference is all in the tail housing. While I don't think I will mind the shorter trans in the long run they need to tell people what they are getting. Their manual even states the 29.25" length on the cover. I wish I had double checked everything and caught this before the original fabrication and install but I trusted that it was what they said it was when I purchased it. Back to waiting for a response.

Post by **Kinder** » Mon Jul 03, 2017 11:50 am

Wait, a shorter trans does work in your favor with an Atlas, right ? Score one for unintentional good consequences, now if they'll just make good on the replacement.

Post by **pgilbeau** » Mon Jul 03, 2017 2:14 pm

kinder wrote:Wait, a shorter trans does work in your favor with an Atlas, right ? Score one for unintentional good consequences, now if they'll just make good on the replacement.

It works in my favor as long as they provide an equivalent replacement. The only real drawback is that I will always have to use that combo so if it fails down the road I will have to rebuild whats there and won't be able to grab a regular rebuilt one.

Post by **landshark** » Mon Jul 03, 2017 4:27 pm

I think on the positive side the 2wd zf5 versions should be cheaper and easier to find shouldn't they?

Post by **pgilbeau** » Mon Jul 03, 2017 4:35 pm

landshark wrote:I think on the positive side the 2wd zf5 versions should be cheaper and easier to find shouldn't they?

Actually the part I need is a 4wd rear housing from a 7.3 diesel IDI ZF-5, I started looking for one but they are proving a bit difficult to find. I only started looking in case BC Broncos fails to make good on the warranty and I am already feeling like I am going to be waiting, spoke to them this morning and haven't heard anything back.

Post by **landshark** » Tue Jul 04, 2017 7:59 am

Would the rear housing also be the same from a big block f250-f350 as well? I believe the zf has the same bolt pattern? Could be wrong of course, just trying to open up options, just in case.

Post by **pgilbeau** » Tue Jul 04, 2017 8:25 am

landshark wrote:Would the rear housing also be the same from a big block f250-f350 as well? I believe the zf has the same bolt pattern? Could be wrong of course, just trying to open up options, just in case.

I am not sure if that is an option, I may check it out. From what I have found they used a rear housing that a transfer case or brake could bolt onto for both the 2wd and 4wd diesel ZF-5. I think after this I will at least know the interchanges pretty well.

Post by **pgilbeau** » Wed Jul 05, 2017 4:24 pm

Just got the word they will be sending out another replacement transmission. Hoping everything is right with this one!

Post by **Jesus_man** » Wed Jul 05, 2017 7:39 pm

Yeah, I hope the biggest issue now is just the delay of getting it back in!

Post by **pgilbeau** » Thu Jul 06, 2017 5:21 am

Jesus_man wrote:Yeah, I hope the biggest issue now is just the delay of getting it back in!

X2 on that! This situation has got me thinking about at least keeping spares of the parts to build the shorter ZF-5, I already found a diesel ZF with the shorter rear housing.

Post by **Jesus_man** » Thu Jul 06, 2017 5:36 am

Mine has proven to be a tough tranny. I know it was dropped in straight out of a junkyard. Hard snow bashing caused it to pretty much loose reverse and grind into 3rd. I had it rebuilt somewhere around 2010 and it's been great since! So it just depends on how much you can handle the rig being down in the event of a failure, but I would imagine that spare will be collecting dust for a LONG time!

Post by **pgilbeau** » Thu Jul 06, 2017 5:41 am

Jesus_man wrote:Mine has proven to be a tough tranny. I know it was dropped in straight out of a junkyard. Hard snow bashing caused it to pretty much loose reverse and grind into 3rd. I had it rebuilt somewhere around 2010 and it's been great since! So it just depends on how much you can handle the rig being down in the event of a failure, but I would imagine that spare will be collecting dust for a LONG time!

I agree, already been through a week of Moab and then Holy Cross in the last month and a half and had no problems except the original crack they tried to weld up. I was thinking more along the lines of the fact that they are getting harder to find and I need a different rear housing. Seems like I have started to horde spares of the specific parts for my rig.

Post by **Jesus_man** » Thu Jul 06, 2017 6:11 am

What does the tag on the side of your tranny look like? I'm wondering what mine is for sure! I guess I should get the tape measure out.

Post by **pgilbeau** » Thu Jul 06, 2017 6:25 am

Jesus_man wrote:What does the tag on the side of your tranny look like? I'm wondering what mine is for sure! I guess I should get the tape measure out.

I will get some pictures of my stuff and post them. I was using this site under the details tab to find info:

http://www.smartpartsauto.com/manual_tr ... _5spd.html

Basically mine is a 2wd case with a diesel rear housing, its roughly 1.5 inches shorter.

Post by **pgilbeau** » Fri Jul 21, 2017 8:51 am

Well got the 3rd transmission in and all seems fine except not having much pedal, going to have to spend some time bleeding it better this weekend.

Post by **Jesus_man** » Sat Jul 22, 2017 5:01 am

I don't know what it is but they are difficult to bleed.

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