I just had the throw out bearing go out in my 97 F-250 so i figured while i had the tranny out i would have it rebuilt. When I bought the truck about 6 months ago i would get some grinding while shifting from 1st to 2nd, 4th to 3rd, 3rd to 2nd, 2nd to 1st, and neutral to reverse. I figured it was syncros, so i had a guy rebuild it for me. He put all syncros, shift forks, major overhaul kit, input shaft, reverse gear, and i gave him a shim kit as well. I got the tranny back from him, put it back in the truck, replaced the bushing where the clutch pedal connects to the rod that gows through the firewall, and took it out for a drive. The trannny is a little better but it is still not right. It will still grind if i go into reverse to quick, and the only downshift i can make without any grinding is from 5th to 4th. I don't know much about these zf trannys, so i don't know what else could be the problem. Improperly shimmed parts...? I need to get back to the guy that did the work but I don't know if the problem is caused by more parts that need replaced or if it is something that the mechanic did wrong. Any help would be great. Thanks

 

First off welcome

I had a simular issue with mine two years ago. I had all the sycros replaced and it didnt fix my grinding problem. The guy who rebuilt it took it back and replaced the entire 2nd gear assembly. That fixed that problem, but now 3rd is doing the same thing .

You might want to replace the clutch slave cylinder, mine had rust in it and seemed to affect the travel of the clutch.

Also what type of fluid did you use? I am going to replace my motorcraft atf with royal purple syncromax to see if it helps out a little.

 

ive been having a similar problem also. when i go into reverse, it often grinds. also, if i shift to 5th too quickly it will grind slightly and feel like the clutch goes straight to the floor.

 

I had a similar problem a few years back and it ended up being the pedistal that the clutch and brake pedals are connected to up under the dash. It was cracked and it gave just enough to keep the pedal from going far enough to completly disengage, giving me that grind when I shifted. This may not be your problem but something to look at. Good luck with it guys!

 

unless you did the fix on the bushing for the clutch linkage it will be shot in 2-3 weeks, I replaced mine and in 3 weeks it was totally worn through. I cut the crown parts off the next bushing, pulled the whole assy and tapped the shaft the bushing slides over to stick a nyloc nut on...havent had a problem since. Just replacing the bushing wont do any good. This wont be your major source of grinding, but soon it will add to more grindage.

 

This is all great help. Now I have a couple things to try. Thanks guys