ZF 5 HP-24A Teardown: Step 14: Rear Axle Output Group

We could not remove the F clutch and freewheel until the rear axle parts were removed. So, that was the next step.

To remove this part, we removed the looooong yellow Torx T-40 bolts at the end of the housing.

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We next focused on the flange to which the drive shaft attaches. That area is filthy with black grease, so after trying to tough it out for a while, we gave up and cleaned all the grease off.

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First, we removed the rearmost part.

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With the flange removed, the rearmost portion of the transmission was a plate. We removed the fasteners around that plate, and then removed the plate.

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With the plate removed, the Torsen differential unit can be lifted out.

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The next step is to remove the large rear housing.

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Sandwiched between that housing and the body of the transmission is another housing, perhaps an inch or two thick. We removed that too.

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That enabled us to plainly see the output shaft from transmission, and an intermediate gear that meshes with that. That gear, in turn, also meshes with a gear on a shaft that sends the power to the front differential.

The output shaft of the transmission has some gears and bearings that slide onto it; we removed them.

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We removed the intermediate gear too. Under that gear is a pressed-in bearing that obscures some fasteners that we needed to remove to free the F clutch and freewheel inside the transmission. Removing this bearing was a huge pain. We destroyed the bearing in the process. We tried various pullers and tools, including two special mini-prybars that we’d bought from Snap-On. Finally, the business end of a massive 30mm wrench managed to work the bearing loose. A replacement bearing cost us about $35 plus shipping.

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