I'm still getting my '00 F350, that was very poorly treated by it's previous owner, back into shape. The trans was grinding really bad when changing gears and when I was stopped and put it into first gear. It didn't grind going into reverse or low but it was really hard to get it to shift into them. The clutch pedal felt spongy and had to be all the way on the floor to engage. I had a new clutch put in and I bought the pre filled clutch master and slave cylinder from Ford and installed it. It goes into gear from a stop much better. It will still grind going into first occasionally but not nearly as bad. While driving it still grinds from 1st to 2nd, and 2nd to 3rd. 4th and 5th seem to work just fine. It will down shift from 5th to 4th fine but going from 4th to 3rd it will grind sometimes. Forget going from 3rd to 2nd cause it grinds too bad. I'm thinking synchros unless someone more knowledgable than me has any better ideas. I've called all of the transmission shops around here and none of them rebuild ZF6's. All of them said that if it was the synchros that they would just have to order a remanufactured trans for it. I've checked the salvage yards and $1500 is the cheapest I've found for a used one.

 

Anyone got any ideas?

 

i say synchronizers are dead. time for a rebuild. BTS is a good one to look at.

 

Are you sure the clutch is working properly? I'd change it all out before the transmission. Two many gears with problems to me. If it pulls when in gear and don't ever slip out, I would look at the clutch first.
Chet

 

Yeah I had a new clutch put in it first then I changed out the master and slave. It pulls good when in gear but it has the grinding I mentioned above and it will ocassionally slip out of gear in 1st, 2nd, and 3rd.

 

Just a few q's to help us out:

1.What kind of clutch did you get?
2.Did you/they replace pilot bushing if so what kind was put in?
3.Where is the clutch engaging now compared to before?
4.How many miles are on the truck?
5.Has it ever popped out of gear while driving?
6.Does it feel like it is all the way in gear when you put it in?
7.A.Have you tried double clutching to see if that makes a difference?
7.B OR better question have you tried waiting longer in between taking it out of gear and putting it in the next one to see if that makes a difference? Thus letting the motor slow down more.
8.Have you/do you try and match rpms when shifting?

Um i think that will do for now...

 

1. LUK
2. Not unless it came with the clutch kit.
3. Now it engages between half and 3/4 the way down, before it had to be on the floor.
4. 168k
5. Yes but only in 1st, 2nd, or 3rd and only when I initially shift into those gears.
6. Yes
7A. Yes, before the new clutch it helped some now it makes no difference.
7B. Tried that this morning and it does help a lot.
8. Yes, I try to change gears at around 1700 rpms, seems to do better there.

Thanks,
Chuck

 

# 3 should have said now it engages between half and 3/4 down.