Sealing up the ZF

I made a lot of progress with the ZF.

Half Shaft Plating (Part IV)

I sent the half-shafts in for plating a few weeks ago and picked them up last week.  The plating company recommended cadmium plating for the unmatched corrosion resistance and excellent properties.  It's too bad that cadmium is such a toxic metal; there's really only one non-toxic equivalent plating, which would be gold plating.  Sorry, no gold plating on my car.  I like a yellow chromate finish, but I really like the bare cadmium color without the yellow finish, so I chose to have a clear chromate finish.  I was careful to wash my hands after handling these parts since I don't want any cadmium-related health issues.

Here's a bag of the half shaft nuts and grease seal washers.  Notice the ZF drain plugs, shifter detent, speedometer gear bolt, side detent cover, and top fill plug.

I had the plating company remove all four new U-joints and plate the spiders.  I'm really glad I did it, but wish I could have plated the caps.  Unfortunately I would have to hone each yoke bore to accept this and the press-fit nature may strip some of the plating off.  I'll just apply a clear coat after to keep the caps shiny. The bores of all yoke parts were masked and not plated.

One warning to those who read this blog and want to do what I did- don't plate the splines of the male splined yoke.  There isn't enough clearance between female and male splines to allow for the 0.0005" of plating.  I was warned about the issue but forgot about it.  After picking up the parts, I test-fit the assembly only to find that the two halves didn't slide together without the application of extreme force.  Luckily, I was able to have the plating company dip the splined end in acid and remove the plating.  The two halves now slide effortlessly together.  I have since coated the parts with a satin clear coat, which leaves the metal looking bare and untouched.

Although not related, here's the ZF top fill plug, cadmium plated.  I'll finish everything off with a nice satin clear coat.

Stainless Steel Fasteners for the ZF

I am replacing every piece of hardware possible with stainless steel in addition to painting each major part.  I want the tranny to be easy to clean, look good, and reduce corrosion potential.  I haven't polished each stainless steel bolt as I think it's not necessary for my tastes.  Here's a list of hardware available in stainless steel for a 1971 ZF 5-DS-25-2 transaxle:

M6 socket (allen) head bolts in the following quantities:
2- M6x50 for shifter cover
1- M6x30 for the shifter cover
2- M6x20 for the shifter cover

M8 socket (allen) head bolts in the following lengths and quantities:
14- M8x1.25x25  for lower cover
2- M8x1.25x40 for case halves
4- M8x1.25x50 for lower cover
1- M8x1.25x60 for case halves
1- M8x1.25x80 for case halves
1- M8x1.25x100 for case halves

Lock nuts in the following quantities:
2- M6x1.00 for the shifter detent cover
24- M8x1.25 for the rear cover, case halves, and shifter shaft end cover
25- M10x1.50 for the side covers and bellhousing

Flat washers:
5- 6mm standard flat washers for the shifter cover
10- 8mm standard flat washers for the shifter shaft end cover, and the case halves
5- 10mm standard flat washers for bellhousing nuts

Copper washers:
15- 8mm washers (5/16" washers are equivalent) for the end cover
20- 10mm washers (3/8" washers are equivalent) for the side covers

Please note that the use of a good anti-sieze thread lubricant is recommended.  I use a copper-based anti-sieze thread lubricant.  Stainless steel tends to gall & cause corrosion in aluminum and the anti-sieze will help to reduce that potential.