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my 92 f150 5-speed has been making a rattling noise for a few months now but it still worked fine. when i put the clutch in it stops so must be tranny, would it be a bushing or bearing? just recently it grinds when i put it it 2nd gear mostly when i downshift and once in a while it will grind the slightest in 3rd, do you think these problems are relate or different?
Mine has a little grind going first to second also. I wonder if any chance the line needs to be bled from the slave since I replaced the master cylinder, I only pumped it up and went on my way.
Also, How does one inspect the syncros? I have my top cover off the trans to replace those three back seals so that would be the best time, I'd hope.
If you don't see noticeable wear or chipped teeth, you may be able to smooth up the shifting and milk some more life out of your trans with some proper manual trans fluid.
Since you have an M5OD, its important to keep the fluid thin for the splash lube design. What you want is a quality MTF/Syncromesh like Pennsoil-syncromesh, Amsoil manual syncromesh transmission fluid, or Redline manual transmission fluid.
THese fluids have a similar viscosity to to ATF to keep the M5OD happy, but have much improved anti-wear additives, and the proper friction modifiers for yellow metal syncros like you have. ATF is very slippery and is not helping your syncros do their jobs.
I have switched my ZF5 over to Pennsoil syncromesh, and now redline, and the shifting is soooooooooooooooooooooo much better now.