I know the ZF5 had a dual mass flywheel clutch setup i also learned there where 11 inch and 12 inch versions..... how do you tell which one you have? and how difficult is it to change one of these clutches? i have never had to change one and mine is still working but im just pricing parts for future reference.... truck has 234,000 miles on it with no service record so the only parts i know i can trust are the ones i have put on it. do they ever really wear out?

the 11 inch one i can get for 180 +
the 12 inch one is 450 +

 

Prices are dropping some, but a dual mass flywheel is close to 1000 dollars.
Throw in another 220 to 250 for the clutch disc, pressure plate and throw out bearing.

Yes they do wear out, and they are expensive to replace.

You can do a single mass flywheel conversion, usually for less money.

However some of the ZF transmissions seem to have a lot of gear roll over noise after the converasion, and it drives some people nuts with all the noise.

When you check the dual mass flywheel, from memory 5/8" rotational free play is the max service limit.
So if you have that much or more, you need to replace the flywheel.

 

how do you check it?

 

as your looking at the flywheel (with or without the pressure plate attached) just turn the pressure plate clockwise and counter clockwise. it will rotate, if its more then 5/8" from lock to lock then the springs are worn out/broken and you need to replace it.

 

can the check be done with the transmission still attached to the engine i dont have anything disassembled its still driveable but id like to check it to see where its at to plan for the future

 

I have a popping noise that happens when the clutch is released and have been told its either in the clutch fork or the throughout bearing by one of the guys i know at autozone and the service dept guys at ford after letting them listen to it i had it happen once before and i messed with the fork a little bit but im thinking about just replacing the throughout bearing this time and i need to know is this the right one

Timken/Clutch Bearing (614062) | Clutch Bearing | 1994 Ford F250 3/4 ton P/U 4WD 8 Cylinders M 7.3L Diesel | AutoZone.com

 

Sachs NFW1069 - Clutch Flywheel 1994 Ford F-250 | O'Reilly Auto Parts

how bout this flywheel? does this one really work on our trucks?

 

Sounds like the Throwout bearing is binding on the nose cone of the transmission ...

-Enjoy
fh : )_~

 

what causes that

 

Burrs, Rust, Lack of grease.

Many people do not apply a light coat of HTEP (High Temp Extreme Pressure) grease to the nose cone when replacing the throwout, it should be done every time it's apart.

-Enjoy
fh : )_~

 

what if its been in there for 236,000 miles

 

any ideas???

 

Same thing, it's dry and binding ... It could have worn into the nose cone, It also could be the pressure plate.

236k, I'd say it's time to do a clutch!

-Enjoy
fh : )_~

 

that wont happen until after the first of the year i dont think i dont really have 500 or 1000 dollars to drop on it right now

 

The inspection cover is removable if you want to check you DMF. I just checked mine as I beleive it's the source of my knock and sqeak. I have about a 1/2" of play in my flywheel and it's only got 133k miles. I plan on going with a south bend conversion set, comes with a new flywheel, clutch set and a kevlar pilot bushing for under $600.