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Hard Shifting Inspection and Verification

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
    • If the fluid level is correct, proceed to the next step in this procedure.
    • If the fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks, and repair as necessary. Refer to CLUTCH CONTROLS . Test the system for normal operation. Proceed to the next step in this procedure, if necessary.
  2. Depress and release the clutch pedal to check for a spongy pedal.
    • If the pedal feels OK, proceed to the next step in this procedure.
    • If the pedal feels spongy, bleed the clutch hydraulic system. Refer to CLUTCH SYSTEM BLEEDING - IN-VEHICLE . Test the system for normal operation. Proceed to the next step in this procedure, if necessary.
  3. Remove the clutch disc and pressure plate. Refer to CLUTCH . Inspect the clutch disc and pressure plate for wear and damage. Refer to CLUTCH PRESSURE PLATE CHECK  and CLUTCH DISC CHECK . Check the clutch release hub and bearing for binding and inspect the guide tube. Inspect the input shaft for wear and damage. If all of the components are OK, proceed to the next step in this procedure. Otherwise, repair all components as necessary. Test the system for normal operation.
  4. Inspect the transmission housing, shafts, forks and synchronizer assemblies. Refer to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED . Repair all components as necessary. Test the system for normal operation.
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