Help..Clutch Pedal Problem
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Freshman User
Joined: Jun 2008
Posts: 39
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Help..Clutch Pedal Problem
So I'm jumping in and out of my truck ('06 SD V-10,6spd)setting up my 5ver at the CG and I'm putting the E-brake on and off as I keep getting in and out,and I go to get back in ,and the clutch pedal is about 4" higher than the brake pedal,the clutch still works fine but the pedal stop must have broke,I get a flshlight and find a broken small (about 1/2") circle clip laying on the floor,I can't seem to find were it goes (when I get another one) I tie wrapped a small block of wood to the E-brake bracket and it makes a good stop with some extra free play,it will get me home just fine,but has anyone had this happen,and where does the C-clip go? Thanks Jack
Elder User
Joined: Feb 2006
Posts: 545
Likes: 5
From: FL
Sorry about your problem . I checked with my Ford Repair Manual , nothing relates to your problem . Here are the symptoms of clutch related problems and Ford recommended solutions . Good luck.
Ken
...........................................
Symptom Chart
SYMPTOM CHART—CLUTCH AND TRANSMISSION OPERATION Condition Possible Sources Action
Clutch Slippage
Clutch pedal binding.
Clutch pressure plate diaphragm spring weakened/damaged.
Clutch pressure plate worn/damaged.
Clutch disc facing worn excessively/damaged.
Clutch disc facing surface hardened or oil coated.
Clutch release hub and bearing binding.
Flywheel glazed/damaged.
CARRY OUT the Clutch Slippage Inspection and Verification procedure in this section.
Clutch Chatter or Shudder
Engine/transmission mount loose/damaged.
Bolts retaining clutch pressure plate to flywheel loose.
Clutch pressure plate worn/damaged.
Clutch disc facing oil coated.
Clutch disc facing hardened/damaged.
Clutch disc runout excessive.
Flywheel surface glazed/damaged.
Flywheel runout excessive.
Transmission input shaft eccentric/not perpendicular.
CARRY OUT the Clutch Chatter or Shudder Inspection and Verification procedure in this section.
Clutch Drag
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
CARRY OUT the Clutch Drag Inspection and Verification procedure in this section.
Clutch Pedal Pulsation
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc runout excessive.
Flywheel runout excessive.
REMOVE the clutch disc and pressure plate. REFER to Section 308-01. INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. CHECK the flywheel runout. REFER to Flywheel Runout Check in this section. REPAIR all components as necessary. TEST the system for normal operation.
Clutch Related Vibrations
Engine component grounding against frame.
Accessory drive belt loose/damaged.
Clutch release bearing worn/damaged.
Bolts retaining clutch pressure plate to flywheel loose.
Bolts retaining flywheel to engine loose.
Flywheel runout excessive.
Clutch pressure plate imbalance.
CARRY OUT the Clutch Chatter or Shudder Inspection and Verification procedure in this section.
Hard Shifting
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch not releasing.
Transmission concern.
CARRY OUT the Hard Shifting Inspection and Verification procedure in this section.
Excessive Noise
Clutch disc damper damaged.
Transmission input shaft pilot bearing (7120) worn/damaged.
Crankshaft end play excessive.
Release bearing worn/damaged.
REMOVE the clutch disc and pressure plate. REFER toSection 308-01. INSPECT the clutch disc for damage. REFER to Clutch Disc Check in this section. INSPECT the transmission input shaft pilot bearing for wear and damage. REFER to Pilot Bearing Check in this section. CHECK the crankshaft end play. Refer to the appropriate section in Group 303 for the procedure. CHECK the clutch release hub and bearing, and guide tube for wear and damage. REPAIR all components as necessary. TEST the system for normal operation.
NOTE: While verifying the condition, determine whether the noise is gear roll-over noise, release bearing rub or some other transmission-related noise. Gear roll-over noise, inherent in manual transmission, is caused by the constant mesh gears turning at engine idle speed while the clutch is engaged and the transmission is in NEUTRAL. Release bearing rub is sometimes mistaken for mainshaft bearing noise. Gear roll-over noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Release bearing rub will disappear when the clutch is engaged. In the event that a bearing is damaged, the noise is more pronounced while engaged in gear under load or coast than in NEUTRAL.
Noisy in Forward Gears
Lubricant level low/incorrect type.
ADD or REFILL with the specified lubricant. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B(ZF 6-Speed Transmission).
Components grounding out on transmission.
CHECK for screws, bolts, etc., of cab or other components grounding out. CORRECT as necessary.
Bolts retaining transmission to engine loose.
VERIFY that the bolts are tightened to specification. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bearings/gears worn/damaged.
INSPECT the bearings, the gears, and the gear teeth for wear and damage. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Gears Clash When Shifting From One Forward Gear to Another
Transmission input shaft pilot bearing worn/damaged.
INSPECT the transmission input shaft pilot bearing for wear and damage. REFER to Pilot Bearing Check in this section. REPAIR as necessary.
Gear teeth/synchronizer damaged.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B(ZF 6-Speed Transmission).
Engine idle speed too high.
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Transmission Jumps Out of Gear
Gearshift lever boot installed incorrectly.
CHECK gearshift lever boot installation. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bolts retaining transmission to engine loose.
TIGHTEN the bolts to specification. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Transmission input shaft pilot bearing.
INSTALL a new transmission input shaft pilot bearing. REFER to Section 308-01.
Axial clearance incorrect.
Internal components damaged.
CHECK axial clearance. INSPECT the synchronizer sleeves for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surface. CHECK the countershaft cluster gear for excessive end play. INSPECT the shift forks for wear. CHECK for loose shift forks on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear and damage. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Gear teeth worn/damaged.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Transmission Will Not Shift Into One Gear — All Others OK
Reversing switch ball frozen in extended position.
INSPECT, and REPAIR as necessary.
Internal components.
For the gear in question, INSPECT the shift rail and fork, the synchronizer, and the gear clutch teeth for restricted travel. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Transmission is Locked in One Gear and Will Not Shift Out of That Gear
Internal components.
INSPECT the gears, the shift rails, and the forks and the synchronizer for wear and damage. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B(ZF 6-Speed Transmission).
Fluid Leaks
Engine, power steering, transmission, clutch.
REMOVE all traces of lubricant on the exposed transmission surfaces. VERIFY that the transmission vent is clear of foreign material. OPERATE the transmission. INSPECT for new leakage. REFER to the appropriate section for repair procedures. REFER to Section 211-02,Section 303-01A, Section 303-01B, Section 303-01C, Section 308-02, Section 308-03A, or Section 308-03B.
Input shaft bearing retainer seal.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Shift rail detent plug.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Top cover gasket.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Sand holes/cracks in case.
INSPECT, and INSTALL a new case as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Fill and drain plugs.
INSPECT the plug, the O-ring, and the threads in the case. REPAIR as necessary. TIGHTEN the plug to specification. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Noise Occurs During Transfer Case Operation
4x4 system.
REFER to Section 308-07A for diagnosis and testing procedures.
Transfer Case Jumps Out of Gear
4x4 system.
REFER to Section 308-07A for diagnosis and testing procedures.
SYMPTOM CHART—TRANSMISSION COMPONENT WEAR AND DAMAGE Condition Possible Sources Action
Case Breakage
Shock loads/alternating loads.
Jerky release of clutch.
INSTALL a new case. REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission). DISCUSS vehicle operation with the customer.
Bolt size/length incorrect.
Bolt threaded into hole incorrectly.
Bolt not tightened to specification.
INSTALL a new case. REPAIR the transmission as necessary. REVIEW the transmission installation procedure. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Shaft Damaged by Brinelling
Vibration.
CORRECT the condition causing the vibration. REFER to Section 100-04for NVH diagnosis.
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure..
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Shaft Damaged by Fretting
Lubricant thermally aged.
Inadequate lubrication.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
Towing vehicle with driveshaft connected.
DISCUSS vehicle towing procedure with the customer.
Gear Teeth Damaged by Scratches
Dust and abrasive particles in lubricant.
DISCUSS transmission maintenance with the customer.
Gear Teeth Damaged by Abrasive Wear
Lubricant contamination resulting from wear or surface fatigue in other areas of transmission.
Foreign material entering transmission.
DISCUSS transmission maintenance with the customer.
Gear Teeth Damaged by Scoring
Lubricant not meeting manufacturer's specification.
Temporary lack of lubricant.
DISCUSS transmission maintenance with the customer.
Brinelling in Gear Teeth
Combination of inadequate lubrication, high flank loads and low peripheral speeds.
DISCUSS transmission maintenance with the customer.
Slight Pittings in Gear Teeth
High local contact pressures on gears not completely run-in.
DISCUSS vehicle operation with the customer. Continued run-in wear and a change in operating conditions may stop this type of pitting.
Gear Teeth with Heavy Pitting Damage
Lubricant viscosity not meeting manufacturer's specification.
Lubricant temperature run too high.
Local sliding and rolling stresses exceed material specification.
DISCUSS transmission maintenance and vehicle operation with the customer.
Gear Teeth Damaged by Spalling
Lubricant not meeting manufacturer's specification.
Lubricant temperature run too high.
DISCUSS vehicle operation and transmission maintenance with the customer.
Overheating and Thermal Gear Deformation
Temporary or complete lack of lubrication.
DISCUSS transmission maintenance with the customer.
Gear Change Damage
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Gear Tooth Corrosion
Water in lubricant.
Condensation forming due to unfavorable operating conditions.
Lubricant aging.
DISCUSS transmission maintenance with the customer.
Idler Gear Damaged by Brinelling
Transmission rebuilt with bearing not meeting manufacturer's specification.
INSTALL a new anti-friction bearing meeting manufacture specification.
Synchronizer Ring Molybdenum Corrosion
Water in lubricant.
DISCUSS transmission maintenance with the customer.
Synchronizer Ring Molybdenum Coat Destruction
Clutching and shifting transmission incorrectly.
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure..
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Synchronizer Ring Broken
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure.
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Synchronizer Friction Cone Slightly Worn
Normal run-in wear.
INSPECT the engaging teeth for wear if a severe, permanent grating condition exists.
Synchronizer Friction Cone Worn with Material Displaced
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Gear Shift Teeth Worn
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Body External Tooth Splines Worn
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure.
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Synchronizer Body Stops Broken
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Sliding Sleeve Stop Deformed
Shift unit set incorrectly.
INSPECT for interference between the shift unit and the vehicle. REPAIR as necessary.
Synchronizer Gear Shift Teeth Worn
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Inner Ring Heat Discolored with Slight Material Displacement
Normal synchronizer operation with high shift effort.
INSPECT the clutch disc and pressure plate for wear and damage. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. CHECK the clutch release hub and bearing for binding, and INSPECT the guide tube. INSPECT the input shaft for wear and damage. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Synchronizer Inner Ring Material Displaced
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Outer Ring Heat Discolored with Slight Material Displacement
Normal synchronizer operation with high shift effort.
INSPECT the clutch disc and pressure plate for wear and damage. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. CHECK the clutch release hub and bearing for binding, and INSPECT the guide tube. INSPECT the input shaft for wear and damage. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Synchronizer Outer Ring Material Displaced
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
General Bearing Wear
Lubricant contaminated.
Lubricant thermally aged.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bearing Worn with Subsequent Damage
Lubricant contaminated.
Lubricant thermally aged.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Vehicle overloading.
DISCUSS vehicle operation with the customer.
Bearing Fatigue
Lubricant contaminated.
Lubricant thermally aged.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bearing Collar Broken
Seizure.
Other transmission or driveline components damaged broken.
Accident damage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Operator error.
DISCUSS vehicle operation with the customer.
Bearing Damaged by Fretting or Seizure
Inadequate lubrication.
DISCUSS transmission maintenance with the customer.
Towing vehicle with driveshaft connected.
DISCUSS vehicle towing procedure with the customer.
Incorrect driveline angles.
CHECK the driveline angles. REFER to Section 205-00.
Sealing Element Radial Shaft Sealing Ring Damaged
Thermal Overload.
Lubricant not meeting manufacturer's specification.
Discuss vehicle operation and transmission maintenance with the customer.
Sealing Element Sealing Lip Worn
Effect of dirt from outside.
Excessive temperatures.
Case vent blocked.
DISCUSS vehicle operation and transmission maintenance with the customer.
Vibration.
CORRECT the condition causing the vibration. REFER to Section 100-04for NVH diagnosis.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Radial shaft sealing ring not pushed in evenly during assembly.
Shaft race damaged.
REVIEW repair procedures. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Sealing Element Rectangular/Lipped Sealing Ring Sheared
Incorrect seal installation.
Damaged by assembly tool.
Incorrect repair.
INSPECT adjacent component contact surfaces, edges, insertion tapers, and REPAIR as necessary. REVIEW repair procedures. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Sealing Element Worn/Hardened
Clutch damage
INSPECT the clutch components, and REPAIR as necessary.
Vehicle overloading.
Inadequate cooling.
Contaminants.
DISCUSS vehicle operation and transmission maintenance with the customer.
Grooves on contact surfaces.
INSPECT component contact surfaces and REPAIR as necessary. REVIEW repair procedures. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
--------------------------------------------------------------------------------
Ken
...........................................
Symptom Chart
SYMPTOM CHART—CLUTCH AND TRANSMISSION OPERATION Condition Possible Sources Action
Clutch Slippage
Clutch pedal binding.
Clutch pressure plate diaphragm spring weakened/damaged.
Clutch pressure plate worn/damaged.
Clutch disc facing worn excessively/damaged.
Clutch disc facing surface hardened or oil coated.
Clutch release hub and bearing binding.
Flywheel glazed/damaged.
CARRY OUT the Clutch Slippage Inspection and Verification procedure in this section.
Clutch Chatter or Shudder
Engine/transmission mount loose/damaged.
Bolts retaining clutch pressure plate to flywheel loose.
Clutch pressure plate worn/damaged.
Clutch disc facing oil coated.
Clutch disc facing hardened/damaged.
Clutch disc runout excessive.
Flywheel surface glazed/damaged.
Flywheel runout excessive.
Transmission input shaft eccentric/not perpendicular.
CARRY OUT the Clutch Chatter or Shudder Inspection and Verification procedure in this section.
Clutch Drag
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
CARRY OUT the Clutch Drag Inspection and Verification procedure in this section.
Clutch Pedal Pulsation
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc runout excessive.
Flywheel runout excessive.
REMOVE the clutch disc and pressure plate. REFER to Section 308-01. INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. CHECK the flywheel runout. REFER to Flywheel Runout Check in this section. REPAIR all components as necessary. TEST the system for normal operation.
Clutch Related Vibrations
Engine component grounding against frame.
Accessory drive belt loose/damaged.
Clutch release bearing worn/damaged.
Bolts retaining clutch pressure plate to flywheel loose.
Bolts retaining flywheel to engine loose.
Flywheel runout excessive.
Clutch pressure plate imbalance.
CARRY OUT the Clutch Chatter or Shudder Inspection and Verification procedure in this section.
Hard Shifting
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch not releasing.
Transmission concern.
CARRY OUT the Hard Shifting Inspection and Verification procedure in this section.
Excessive Noise
Clutch disc damper damaged.
Transmission input shaft pilot bearing (7120) worn/damaged.
Crankshaft end play excessive.
Release bearing worn/damaged.
REMOVE the clutch disc and pressure plate. REFER toSection 308-01. INSPECT the clutch disc for damage. REFER to Clutch Disc Check in this section. INSPECT the transmission input shaft pilot bearing for wear and damage. REFER to Pilot Bearing Check in this section. CHECK the crankshaft end play. Refer to the appropriate section in Group 303 for the procedure. CHECK the clutch release hub and bearing, and guide tube for wear and damage. REPAIR all components as necessary. TEST the system for normal operation.
NOTE: While verifying the condition, determine whether the noise is gear roll-over noise, release bearing rub or some other transmission-related noise. Gear roll-over noise, inherent in manual transmission, is caused by the constant mesh gears turning at engine idle speed while the clutch is engaged and the transmission is in NEUTRAL. Release bearing rub is sometimes mistaken for mainshaft bearing noise. Gear roll-over noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Release bearing rub will disappear when the clutch is engaged. In the event that a bearing is damaged, the noise is more pronounced while engaged in gear under load or coast than in NEUTRAL.
Noisy in Forward Gears
Lubricant level low/incorrect type.
ADD or REFILL with the specified lubricant. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B(ZF 6-Speed Transmission).
Components grounding out on transmission.
CHECK for screws, bolts, etc., of cab or other components grounding out. CORRECT as necessary.
Bolts retaining transmission to engine loose.
VERIFY that the bolts are tightened to specification. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bearings/gears worn/damaged.
INSPECT the bearings, the gears, and the gear teeth for wear and damage. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Gears Clash When Shifting From One Forward Gear to Another
Transmission input shaft pilot bearing worn/damaged.
INSPECT the transmission input shaft pilot bearing for wear and damage. REFER to Pilot Bearing Check in this section. REPAIR as necessary.
Gear teeth/synchronizer damaged.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B(ZF 6-Speed Transmission).
Engine idle speed too high.
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Transmission Jumps Out of Gear
Gearshift lever boot installed incorrectly.
CHECK gearshift lever boot installation. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bolts retaining transmission to engine loose.
TIGHTEN the bolts to specification. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Transmission input shaft pilot bearing.
INSTALL a new transmission input shaft pilot bearing. REFER to Section 308-01.
Axial clearance incorrect.
Internal components damaged.
CHECK axial clearance. INSPECT the synchronizer sleeves for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surface. CHECK the countershaft cluster gear for excessive end play. INSPECT the shift forks for wear. CHECK for loose shift forks on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear and damage. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Gear teeth worn/damaged.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Transmission Will Not Shift Into One Gear — All Others OK
Reversing switch ball frozen in extended position.
INSPECT, and REPAIR as necessary.
Internal components.
For the gear in question, INSPECT the shift rail and fork, the synchronizer, and the gear clutch teeth for restricted travel. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Transmission is Locked in One Gear and Will Not Shift Out of That Gear
Internal components.
INSPECT the gears, the shift rails, and the forks and the synchronizer for wear and damage. REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B(ZF 6-Speed Transmission).
Fluid Leaks
Engine, power steering, transmission, clutch.
REMOVE all traces of lubricant on the exposed transmission surfaces. VERIFY that the transmission vent is clear of foreign material. OPERATE the transmission. INSPECT for new leakage. REFER to the appropriate section for repair procedures. REFER to Section 211-02,Section 303-01A, Section 303-01B, Section 303-01C, Section 308-02, Section 308-03A, or Section 308-03B.
Input shaft bearing retainer seal.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Shift rail detent plug.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Top cover gasket.
INSPECT, and REPAIR as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Sand holes/cracks in case.
INSPECT, and INSTALL a new case as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Fill and drain plugs.
INSPECT the plug, the O-ring, and the threads in the case. REPAIR as necessary. TIGHTEN the plug to specification. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Noise Occurs During Transfer Case Operation
4x4 system.
REFER to Section 308-07A for diagnosis and testing procedures.
Transfer Case Jumps Out of Gear
4x4 system.
REFER to Section 308-07A for diagnosis and testing procedures.
SYMPTOM CHART—TRANSMISSION COMPONENT WEAR AND DAMAGE Condition Possible Sources Action
Case Breakage
Shock loads/alternating loads.
Jerky release of clutch.
INSTALL a new case. REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission). DISCUSS vehicle operation with the customer.
Bolt size/length incorrect.
Bolt threaded into hole incorrectly.
Bolt not tightened to specification.
INSTALL a new case. REPAIR the transmission as necessary. REVIEW the transmission installation procedure. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Shaft Damaged by Brinelling
Vibration.
CORRECT the condition causing the vibration. REFER to Section 100-04for NVH diagnosis.
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure..
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Shaft Damaged by Fretting
Lubricant thermally aged.
Inadequate lubrication.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
Towing vehicle with driveshaft connected.
DISCUSS vehicle towing procedure with the customer.
Gear Teeth Damaged by Scratches
Dust and abrasive particles in lubricant.
DISCUSS transmission maintenance with the customer.
Gear Teeth Damaged by Abrasive Wear
Lubricant contamination resulting from wear or surface fatigue in other areas of transmission.
Foreign material entering transmission.
DISCUSS transmission maintenance with the customer.
Gear Teeth Damaged by Scoring
Lubricant not meeting manufacturer's specification.
Temporary lack of lubricant.
DISCUSS transmission maintenance with the customer.
Brinelling in Gear Teeth
Combination of inadequate lubrication, high flank loads and low peripheral speeds.
DISCUSS transmission maintenance with the customer.
Slight Pittings in Gear Teeth
High local contact pressures on gears not completely run-in.
DISCUSS vehicle operation with the customer. Continued run-in wear and a change in operating conditions may stop this type of pitting.
Gear Teeth with Heavy Pitting Damage
Lubricant viscosity not meeting manufacturer's specification.
Lubricant temperature run too high.
Local sliding and rolling stresses exceed material specification.
DISCUSS transmission maintenance and vehicle operation with the customer.
Gear Teeth Damaged by Spalling
Lubricant not meeting manufacturer's specification.
Lubricant temperature run too high.
DISCUSS vehicle operation and transmission maintenance with the customer.
Overheating and Thermal Gear Deformation
Temporary or complete lack of lubrication.
DISCUSS transmission maintenance with the customer.
Gear Change Damage
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Gear Tooth Corrosion
Water in lubricant.
Condensation forming due to unfavorable operating conditions.
Lubricant aging.
DISCUSS transmission maintenance with the customer.
Idler Gear Damaged by Brinelling
Transmission rebuilt with bearing not meeting manufacturer's specification.
INSTALL a new anti-friction bearing meeting manufacture specification.
Synchronizer Ring Molybdenum Corrosion
Water in lubricant.
DISCUSS transmission maintenance with the customer.
Synchronizer Ring Molybdenum Coat Destruction
Clutching and shifting transmission incorrectly.
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure..
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Synchronizer Ring Broken
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure.
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Synchronizer Friction Cone Slightly Worn
Normal run-in wear.
INSPECT the engaging teeth for wear if a severe, permanent grating condition exists.
Synchronizer Friction Cone Worn with Material Displaced
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Gear Shift Teeth Worn
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Body External Tooth Splines Worn
Driving at low road speed in a high gear.
DISCUSS vehicle operation with the customer.
Engine related factors (such as crankshaft vibration damper damaged).
CORRECT as necessary. Refer to the appropriate section in Group 303 for the procedure.
Driveshaft imbalance.
CORRECT the driveshaft imbalance. REFER to Section 205-00.
Synchronizer Body Stops Broken
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Sliding Sleeve Stop Deformed
Shift unit set incorrectly.
INSPECT for interference between the shift unit and the vehicle. REPAIR as necessary.
Synchronizer Gear Shift Teeth Worn
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Inner Ring Heat Discolored with Slight Material Displacement
Normal synchronizer operation with high shift effort.
INSPECT the clutch disc and pressure plate for wear and damage. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. CHECK the clutch release hub and bearing for binding, and INSPECT the guide tube. INSPECT the input shaft for wear and damage. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Synchronizer Inner Ring Material Displaced
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
Synchronizer Outer Ring Heat Discolored with Slight Material Displacement
Normal synchronizer operation with high shift effort.
INSPECT the clutch disc and pressure plate for wear and damage. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. CHECK the clutch release hub and bearing for binding, and INSPECT the guide tube. INSPECT the input shaft for wear and damage. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Synchronizer Outer Ring Material Displaced
Insufficient clutch hydraulic system fluid.
Clutch hydraulic system fluid leakage.
Air in clutch hydraulic system.
Clutch pressure plate worn/damaged.
Clutch disc damaged.
Clutch disc splines rusted/worn.
Clutch disc runout excessive.
INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and to Clutch Disc Check in this section. VERIFY that the clutch hydraulic fluid reservoir is filled to the correct level. ADD fluid as necessary. INSPECT the clutch hydraulic system for leaks, and REPAIR as necessary. REFER to Section 308-02. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding—In-Vehicle in this section. TEST the system for normal operation.
Clutching and shifting transmission incorrectly.
DISCUSS vehicle operation with the customer.
General Bearing Wear
Lubricant contaminated.
Lubricant thermally aged.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bearing Worn with Subsequent Damage
Lubricant contaminated.
Lubricant thermally aged.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Vehicle overloading.
DISCUSS vehicle operation with the customer.
Bearing Fatigue
Lubricant contaminated.
Lubricant thermally aged.
Lubricant not meeting manufacturer's specification.
DISCUSS transmission maintenance with the customer.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Bearing Collar Broken
Seizure.
Other transmission or driveline components damaged broken.
Accident damage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Operator error.
DISCUSS vehicle operation with the customer.
Bearing Damaged by Fretting or Seizure
Inadequate lubrication.
DISCUSS transmission maintenance with the customer.
Towing vehicle with driveshaft connected.
DISCUSS vehicle towing procedure with the customer.
Incorrect driveline angles.
CHECK the driveline angles. REFER to Section 205-00.
Sealing Element Radial Shaft Sealing Ring Damaged
Thermal Overload.
Lubricant not meeting manufacturer's specification.
Discuss vehicle operation and transmission maintenance with the customer.
Sealing Element Sealing Lip Worn
Effect of dirt from outside.
Excessive temperatures.
Case vent blocked.
DISCUSS vehicle operation and transmission maintenance with the customer.
Vibration.
CORRECT the condition causing the vibration. REFER to Section 100-04for NVH diagnosis.
High mileage.
REPAIR the transmission as necessary. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Radial shaft sealing ring not pushed in evenly during assembly.
Shaft race damaged.
REVIEW repair procedures. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Sealing Element Rectangular/Lipped Sealing Ring Sheared
Incorrect seal installation.
Damaged by assembly tool.
Incorrect repair.
INSPECT adjacent component contact surfaces, edges, insertion tapers, and REPAIR as necessary. REVIEW repair procedures. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
Sealing Element Worn/Hardened
Clutch damage
INSPECT the clutch components, and REPAIR as necessary.
Vehicle overloading.
Inadequate cooling.
Contaminants.
DISCUSS vehicle operation and transmission maintenance with the customer.
Grooves on contact surfaces.
INSPECT component contact surfaces and REPAIR as necessary. REVIEW repair procedures. REFER to Section 308-03A (Model S5-47ZF Transmission) or Section 308-03B (ZF 6-Speed Transmission).
--------------------------------------------------------------------------------
Elder User
Joined: Feb 2006
Posts: 545
Likes: 5
From: FL
Sorry about your problem . I checked with my Ford Repair Manual , nothing relates to your problem . Here are the symptoms of clutch related problems and Ford recommended solutions . Good luck.
Ken
...........................................
Symptom Chart
Ken
...........................................
Symptom Chart
Last edited by Wolfboro; Jul 27, 2010 at 06:45 PM. Reason: Double posted
Thread Starter
|
Freshman User
Joined: Jun 2008
Posts: 39
Likes: 0
Thanks for the info,but I figured it out and fixed it,the snap ring holds the piston (and rod) from coming out the back of the clutch master cyl.,problem is the cyl. is coverered by a spring loaded switch,(clutch start and cruise kick off)that covers everything up,the clip goes back inside the master cyl.about 3/8 of an inch,I had a bent pair of snap ring pliers from in the '70s when I work at a Ford dealer that had the right bend to get that clip back in there....only took about 3 hrs.!!!!! What a nightmare....the clip is .750 diam. if you ever need one.My advice is if this ever happens to you,find a 1x1x6" long block of wood,put it on top the E-brake release bracket,wrap a tie wrap around it and drive it until you have a couple hrs.to fix it,or take it to your Dealer!
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