Hi there. New first time ford owner here. 96 F150 4x4 with 300/6 and M5OD mazda tranny. 145k miles on it and looking really clean, and just the truck we wanted. It used to be well cared for, but has been a bit neglected since the owner passed away.

I spent a few hours searching the forums here and didn't find anything matching my symptoms exactly so I thought I would just jump in a post, but if I missed a thread feel free to redirect me.

I've got a bit of a rattling noise as the clutch engages when taking off in first. Once the clutch is fully engaged it's quiet and it shifts well and smooth. Noise also occurs (but less so) if I don't match RPM's and ride the clutch into second or third. I don't think its engine noise from lugging or anything because it goes away as soon as the clutch is fully engaged or disengaged.

Changed the trans fluid last night and no different, Clutch fluid reservoir is full, clutch travel feels good, master cylinder looks good, (slave is hidden, but looks dry though dust cover) a little play in the white bushing that holds the clutch pedal bar in place, and the plastic pushrod that goes into the firewall, thinking about replacing this linkage.

I work on big diesels for a living so i'm not scared of getting greasy.

Any suggestions? I'm almost inclined to think someone did a clutch job without resurfacing the flywheel. Is there an improved replacement for the pedal bracket and linkage? I don't mind just doing the clutch, but I don't want to be throwing my money away.

Thanks.

 

Clutch, Transmission, Differential, Axle & Transfer Case - Ford Truck Enthusiasts Forums

Try that Forum.