Friends,
I took my 1995 f-150 to my local dealer @ 100,00 mi for a “look over.” The service manager told me that I should replace the original clutch. I let them do so. When I went to pick up my truck they were starting it for the first time with the new clutch. After about 20 sec the pressure plate broke into many pieces causing a lot of damage to my truck. The ford dealer did me right in replacing all the damaged parts, including a new transmission case, starter, flywheel, and of course, a new clutch set.

The problem is: since them the ford dealer has installed 9 more clutches over a period of 5000 mi. Reason being: clutch chatter. I have read a lot of your postings and chatter seems to be a problem you all live with and accept. Since my truck did not have this problem before the ford service guys got a hold of it I am insisting they fix it. Does any one know what they might be doing wrong? It is a 4x2, straight 6, xlt. I have a meeting tomorrow with the dealer manager and service manager.

Thank you
Chris
thumper@bright.net

 

Thumper ,
I must say 9 clutch R&R 's in 5000 miles is a lot . My guess is that they are ham stinging you ...Have you actually seen the truck tore down and them replacing any of the 9 clutches ? It just sounds very unusual . If you have taken the truck back to them for the chattering problem , Id say they are just trying to smooze you until you go away . They dont want to do the work for free given that clutch chattering is a common complaint .On an earlier post I read , replacing the flywheel seemed to cure the chattering and it makes sense . You said they replaced the flywheel when the pressure plate went to hell on the first clutch replacement .I had a friend w a Chevy truck w a real seal leak ...they kept telling him it was the valve covers ...they didnt want to do the work under warranty because it doesnt pay their techs the same as if it were an out of warranty deal , plus the dealer makes no money on the repair .The same hold true for Ford or any other dealer. Its a weird dance you have to do w dealers and their higher ups to get some satisfaction . Plus you have to consider the age of the vehicle , if you have been the sole owner . If you cant get them to fix things to your satisfaction , go someplace else . A lot of independant shops do solid work on Fords . Dont always fall into the dealer telling you your truck needs to be fixed ...Ive driven mine home on 5 cyl , and odd size tire , a hole in the rad held together w Bars Leak , a broken motor mount and one headlight ...Ford Trucks are very tough and most of the time only require some common sense repairs to make them better . Just make sure you know what they are doing to your truck .
Paul

 

yea i think your right, but i stop by and stick my head in the shop from time to time. i have actually seen the clutches layed out on a been, and i have copies of the iinvoces. if they are screwing me, they are also screwing ford for the warantee clutches. i hold no faith in any one working on my truck. i just fell into some money and i knew my clutch was going, and thought it wqould be a good present to mysely.

i ripped the delaer owner a new *ss on the phone today just to keep them straight. he told me i could have dinner with his attorney... i daid i'd pay and make the reservation. it is getting pretty hatefull. wednesday i am taking my truck bak for clutch 11. they understand that i will watch the whole change out. outta be intresting

 

When you turn the thing over to this dealer, do this:
1. Have them put a dial indicator on that flywheel and show both you and them that runout is within service specifications;
2. Grind that flywheel flat no matter how correct that runout reading is;
3. Retap all clutch cover bolts holes in that flywheel and COUNTERSINK THE FIRST THREAD!;
4. Retap the flywheel bolt holes in the crankshaft;
5. Replace the pilot bushing;
6. HAND TORQUE ALL BOLTS;
7. The 300-6 flywheel is predrilled for both a ten-inch and an eleven-inch clutch...make 'em give you an eleven. Pay them the difference if they whine about it, it's not much more expensive;
8. Make absolutely sure they give you a brand-new, brand-name throwout bearing AND hydraulic unit. They will tell you that those two pieces are not separate. Well, they are, and no matter if you only have one mile on them you want new ones.
9. Make them use a clutch alignment tool when they assemble your disc and pressure plate.
10. Pay attention to all the bolts they use; make sure they are flywheel and clutch cover bolts. All those pieces are specialized, and will fail in some way if hardware store pieces are used.
Mostly, make sure they have a flat mating surface for the friction members, and do some quality work.
Ed

 

I totaly agree with Ed. Also have them check the run out on the transmission input shaft, I believe there is a spec in the service book for that. Also make them check to make sure the face of the trans ,where it bolts to the engine, if square to the shaft. I have seen some trannys in junkyards that have come from burned vehicles, they look warped and melted. The heat could warp the whole case, cause shaft misalignments, and can take the temper out of the shafts and gears. The dealer probable replaced the whole tranny rather than tear everything down and put your guts in a new case.
Steve

 

i did finally get this fixed. turns out that the pressure plates that the for dealer was putting in were defective. all you ford guys with clutch chatter better look at this more closely. the fingers on the pressure plate are held to a high tolerance. @.020" FROM THE FACTORY ON NEW, AND A LOT MORE ON "REMANUFACTURED," which is what the ford dealer puts on your truck when they quote you a new assembly. One of the 9 pressure plates the ford dealer put on my truck was out more that .25". the service manager & the dealer manager did not seem to care. in his opinion, Randy Larue @ kerns ford in Saint Marys Ohio, said that the probability of a bad pressure plate is not likley. yea right! this would deffinately cause chatter in any situation. ask to inspect all cluth parts when a dealer is installing a clutch. it would have saved me several months of being pissed off had i done this the first time. ford trucks do not have to live with clutch chatter! just bad parts!

 

Although I'm a little late on this since you've already got it taken care here's something else to watch out for on clutch jobs. I was going through clutches about every six months, everytime I'd rebuild it I'd do the complete job including turning the flywheel. I finally discovered that the culprit was a worn front bearing retainer on the trans. (It's the shaft the throwout bearing rides on.) It was cone shaped causing the the throwout bearing to engage unevenly.

Trail Rider

 

Edd is your dad a doc your unusual name was my neighbor's also when he was in college? Your opions are right on but when I scattered a clutch on my 96 it also bent the input shaft on the trans. and the crankshaft was bet .020 about half way acrossed the flywheel face.