zf5 Clutch issues
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5th Wheeling
Joined: Jul 2017
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zf5 Clutch issues
I have searched these forums and other websites and havent found any straight answers. My truck has been grinding and hard shifting for awhile. New pedalbox bushings and bushing on clutch master rod. New pre bled Clutch master and slave installed. Have read things about clutch fork being bent or cracked. How do I measure clutch travel and figure out if I need a new clutch or fork. It seems to be there are many things that can cause these issues, like dropping the inspection cover and tightening bolts on the clutch can fix this. Also if this issue is caused by a bad clutch fork, can it be fixed without dropping the tranny. Please help, i cant find any answers, thanks.
Lead Driver
Joined: Sep 2002
Posts: 9,576
Likes: 2,039
From: North Texas
Does it shift like that in all gears?
Mine sounds the worst on a 4-5 upshift, but if I let the engine RPM drop to idle then make the shift around 45mph for me... it is fairly smooth without excess noise. 2-3 is pretty bad on mine when cold. 3-4 is good and 1-2 is decent.
This may sound dumb, but is the thing full of the correct fluid, being ATF? How about the shift bushings?
It cannot hurt to drop the the trans and inspect the clutch, TOB, pilot bearing, etc. There are plenty of hack 'mechanics' around and I have been fixing piles of those 'repairs' on my new to me F350.
Mine sounds the worst on a 4-5 upshift, but if I let the engine RPM drop to idle then make the shift around 45mph for me... it is fairly smooth without excess noise. 2-3 is pretty bad on mine when cold. 3-4 is good and 1-2 is decent.
This may sound dumb, but is the thing full of the correct fluid, being ATF? How about the shift bushings?
It cannot hurt to drop the the trans and inspect the clutch, TOB, pilot bearing, etc. There are plenty of hack 'mechanics' around and I have been fixing piles of those 'repairs' on my new to me F350.
Laughing Gas
Joined: Jan 2016
Posts: 910
Likes: 96
From: Fl.
madpogue posted this on 10-21-16 to help some one (get under the truck with a measuring tape while an assistant works the pedal. Measure fork travel at the tip. Should be 1/2" to 9/16" minimum. If it's less, trouble is "upstream" - hydraulics, pedal box bushings, arm/pushrod connection, arm orientation, etc. If there is at least minimum movement, that stuff is all okay and trouble is "downstream" - fork, throwout, pressure plate fingers, etc.) may be it will help you
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5th Wheeling
Joined: Jul 2017
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Just measured the clutch travel. Seems like I have 7/8 in of travel which is over spec. As far as I know it has the original dual mass clutch in it. i bought the truck with 69k and it has 75k on it now.
Laughing Gas
Joined: Jan 2016
Posts: 910
Likes: 96
From: Fl.
That is not a lot of mi. even on a duel mass . How much free play up and down in the peddle before the clutch starts to get some pressure? You may have to re-clock the arm for the clutch rod a bit. Someone did this just a few weeks ago. If all else is tight idk Looks like you have enough travel on the clutch release bearing arm. Someone will have some more insight
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