Gear clash
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Elder User
Joined: Jun 2004
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From: La Crosse, Kansas
Gear clash
I've had this problem for about the last year or so, it doesn't seem to be getting any worse, but here goes. When upshifting into 2nd gear with no load, there will be a noise that sounds like gears clashing. this also happens when downshifting into 2nd 9 out of 10 times. i replaced the clutch with a OEM unit and adjusted the linkages to factory specs, and this didnt solve anything. i changed the tranny fluid and added synthetic, and this didn't help any either. anyone else have this problem with the 5 spd manual? it's embarassing and annoying. any help would be appreciated. i took it to my local ford dealership, and they said the clutch, even though i had just replaced it months ago. so they were no help. any help or suggestions on what to check would be much appreciated.
Lead Driver
Joined: May 2003
Posts: 9,303
Likes: 48
From: Lyndonville, Vermont
I don't know about special tools. maybe not you might be able to get by. You will need the best literature you can get..Sounds like you could handle it..Books will tell you about the tools.
Dick
Dick
Post Fiend
Joined: Jan 2002
Posts: 5,859
Likes: 7
From: USA
Is this truck a manual shift transfer case ?
I know its a 5sp zf .
How many miles on the truck?
as 99 said if the syncro is worn or bad it will grind every time
hears something to do if you have a manual transfercase
put transfercase in neutral ,set parking brake,shift through your gears rolldown windows and listen to the rollover noise in every gear,especially second gear if its considerably louder.I would suspect you have and internal trans problem.
These trannies are setup by endplay an a torque nut.when the become worn
this is when they star jumping out of gear under load.
The clutch, if you can
shift from first to rev without grinding ,I don't think you have a clutch problem.
if you have electric shift the above procedure can't be done.
When you changed the tranny fluid any excess chips in the fluid.
Rich
sorry didn't see your responses to 99
Special tools are needed and 2 big strong people these trannys are huge!
I have a 6sp zf
I know its a 5sp zf .
How many miles on the truck?
as 99 said if the syncro is worn or bad it will grind every time
hears something to do if you have a manual transfercase
put transfercase in neutral ,set parking brake,shift through your gears rolldown windows and listen to the rollover noise in every gear,especially second gear if its considerably louder.I would suspect you have and internal trans problem.
These trannies are setup by endplay an a torque nut.when the become worn
this is when they star jumping out of gear under load.
The clutch, if you can
shift from first to rev without grinding ,I don't think you have a clutch problem.
if you have electric shift the above procedure can't be done.
When you changed the tranny fluid any excess chips in the fluid.
Rich
sorry didn't see your responses to 99
Special tools are needed and 2 big strong people these trannys are huge!
I have a 6sp zf
Last edited by FortyFords; Aug 18, 2004 at 10:57 PM.
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Elder User
Joined: Jun 2004
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From: La Crosse, Kansas
what books are available out there? my local autozone and oreilly's don't carry the Chilton's or Hayne's manuals for them, and they're shady about getting them. is there somewhere that i can get a service manual?
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Post Fiend
Joined: Jan 2002
Posts: 5,859
Likes: 7
From: USA
Thread Starter
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Elder User
Joined: Jun 2004
Posts: 883
Likes: 2
From: La Crosse, Kansas
who makes the 5spd trannys? i did the above test that you listed Rich, and there is some resistance/noise when shifting into 2nd. i noticed some chips in the the oil, but figured it was somewhat normal since the truck has 85,000 miles and hasn't ever had a tranny fluid change. what causes the synchronizer to wear so quickly? every truck ive had has been manual, and none of them had this problem and they had higher mileage.
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Elder User
Joined: Jun 2004
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From: La Crosse, Kansas
at the site you list Rich, they don't have that new of a transmission available that i could find. could i find the parts at an oreilly's (hate AutoZone with a passion) or is this something id have to get at the dealer?
Lead Driver
Joined: May 2003
Posts: 9,303
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From: Lyndonville, Vermont
Dealer mostly but sometimes you can hook up with a good tranny shop to get your parts. usually no auto parts store will carry manual tranny parts.
Don't mean to answer for you Forty.
Dick
Don't mean to answer for you Forty.
Dick
Post Fiend
Joined: Jan 2002
Posts: 5,859
Likes: 7
From: USA
The tranny is made by a german company here in the us and overseas
www.zf.com
The other site has rebuild kits for your tranny
If you want a manual you can go to ebay get the cd or go to www.helminc.com and buy the shop manual for your truck.
none of the big autopart stores carry any parts for these trannys.
Rich
Not a problem 99
www.zf.com
The other site has rebuild kits for your tranny
If you want a manual you can go to ebay get the cd or go to www.helminc.com and buy the shop manual for your truck.
none of the big autopart stores carry any parts for these trannys.
Rich
Not a problem 99