Symptom Chart

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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 article.
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 article.
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 article.
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 CLUTCH article. INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and Clutch Disc Check in this article. 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 article.
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 article.
Excessive noise	Clutch disc damper damaged. Transmission input shaft pilot bearing worn/damaged. Crankshaft end play excessive. Release bearing worn/damaged.	REMOVE the clutch disc and pressure plate. REFER to CLUTCH article. 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 article. CHECK the crankshaft end play. Refer to the appropriate Engine article 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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Bearings/gears worn/damaged.	INSPECT the bearings, the gears, and the gear teeth for wear and damage. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
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 article. REPAIR as necessary.
	Gear teeth/synchronizer damaged.	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Engine idle speed too high.	REFER to the Content Not Found article.
Transmission jumps out of gear	Gearshift lever boot installed incorrectly.	CHECK gearshift lever boot installation. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Bolts retaining transmission to engine loose.	TIGHTEN the bolts to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Transmission input shaft pilot bearing.	INSTALL a new transmission input shaft pilot bearing. REFER to CLUTCH article.
	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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Gear teeth worn/damaged.	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
Transmission will not shift into one gear - all others OK	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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
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 POWER STEERING article, ENGINE - 5.4L (3V) article, ENGINE - 6.8L (3V) article, ENGINE - 6.0L DIESEL article, CLUTCH CONTROLS article or MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Input shaft bearing retainer seal.	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Shift rail detent plug.	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Top cover gasket.	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Power take-off (PTO) cover.	INSPECT and REPAIR as necessary. INSTALL a new gasket. TIGHTEN to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Sand holes/cracks in case.	INSPECT and INSTALL a new case as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
Noise occurs during transfer case operation	4x4 system.	REFER to FOUR WHEEL DRIVE (4WD) SYSTEMS article for diagnosis and testing procedures.
Transfer case jumps out of gear	4x4 system.	REFER to FOUR WHEEL DRIVE (4WD) SYSTEMS article 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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article. 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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
Shaft damaged by brinelling	Vibration.	CORRECT the condition causing the vibration. REFER to NOISE, VIBRATION AND HARSHNESS article for 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 Engine article for the procedure.
	Driveshaft imbalance.	CORRECT the driveshaft imbalance. REFER to DRIVELINE SYSTEM - GENERAL INFORMATION article.
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.	PINPOINT the source of water. REPAIR as necessary. 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 Engine article for the procedure.
	Driveshaft imbalance.	CORRECT the driveshaft imbalance. REFER to DRIVELINE SYSTEM - GENERAL INFORMATION article.
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 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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 Engine article for the procedure.
	Driveshaft imbalance.	CORRECT the driveshaft imbalance. REFER to DRIVELINE SYSTEM - GENERAL INFORMATION article.
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. Clutch pedal not completely depressed.	INSPECT the clutch disc and pressure plate for wear and damage, and CHECK the clutch disc runout. REFER to Clutch Pressure Plate Check and 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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 Engine article for the procedure.
	Driveshaft imbalance.	CORRECT the driveshaft imbalance. REFER to DRIVELINE SYSTEM - GENERAL INFORMATION article.
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 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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. Clutch spin down time not correct (dragging).	INSPECT the clutch disc and pressure plate for wear and damage. REFER to Clutch Pressure Plate Check and Clutch Disc Check in this article. 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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 Clutch Disc Check in this article. 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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 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 CLUTCH CONTROLS article. BLEED the clutch hydraulic system as necessary. REFER to Clutch System Bleeding - In-Vehicle in this article. 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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
Bearing collar broken	Seizure. Other transmission or driveline components damaged broken. Accident damage.	REPAIR the transmission as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	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 DRIVELINE SYSTEM - GENERAL INFORMATION article.
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 NOISE, VIBRATION AND HARSHNESS article for NVH diagnosis.
	High mileage.	REPAIR the transmission as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
	Radial shaft sealing ring not pushed in evenly during assembly. Shaft race damaged.	REVIEW repair procedures. REFER to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.
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 MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article.