Symptom Chart - Transmission (Manual) And Transfer Case Noise/Vibration

SYMPTOM CHART - TRANSMISSION MANUAL AND TRANSFER CASE NOISE/VIBRATION

Condition	Possible Sources	Action
Clutch rattling noise-occurs with clutch engaged, noise changes/disappears with clutch pedal depressed	Flywheel bolts, clutch housing bolts or clutch pressure plate bolts loose.	TIGHTEN the bolts to specifications. CHECK the bolts for damage.
Clutch squeaking noise - noise is heard when the clutch is operated. Vehicle moves slowly or creeps when the clutch is disengaged. Can also be difficult to shift into first and reverse gear	Pilot bearing seized or damaged.	INSTALL a new pilot bearing. REFER to CLUTCH CONTROLS .
Clutch squeaking noise-occurs with clutch pedal depressed/released	Worn clutch pedal shaft or bushings.	INSPECT the clutch pedal for wear or damage. REPAIR as necessary. REFER to CLUTCH CONTROLS .
Clutch whirring/rattle noise - occurs when clutch pedal is depressed	Worn, damaged or misaligned clutch release bearing.	INSTALL a new clutch release bearing. REFER to CLUTCH .
Clutch grating/grinding noise - occurs when clutch pedal is depressed	Clutch pressure plate fingers bent or worn.	INSPECT the clutch pressure plate release fingers. INSTALL a new pressure plate as necessary. REFER to CLUTCH .
	Contact surface of clutch release bearing worn or damaged.	INSTALL a new clutch release bearing. REFER to CLUTCH CONTROLS .
Clutch chatter - a small amount of noise when clutch pedal is released at initial take-off	Clutch engagement.	Acceptable operating condition.
Clutch chatter/grabs-in some cases a shudder is felt. Occurs with clutch pedal depressed/released	Damaged or worn powertrain/driveline mounts.	INSPECT the powertrain/drivetrain mounts. INSTALL new mounts as necessary. REFER to ENGINE- 3.8L & 3.9L for 3.8L engines or ENGINE- 4.6L (2V) for 4.6L (2V) engines.
	Binding or dragging plunger of the clutch master cylinder or slave cylinder.	CHECK the master and slave cylinder operation. INSPECT the components for damage or wear. INSTALL a new master or slave cylinder as necessary. REFER to CLUTCH CONTROLS .
	Grease or oil on the clutch disc facing.	CHECK the input shaft seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch disc. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Clutch disc surface glazed or damaged.	INSPECT the clutch disc surface for a glazed, hardened or damage condition. CARRY OUT a disc check. INSTALL a new clutch disc as necessary. REFER to CLUTCH .
	Damaged or worn clutch pressure plate.	INSPECT the clutch pressure plate for wear or damage. INSTALL a new clutch pressure plate as necessary. REFER to CLUTCH .
	Flywheel surface damaged or glazed.	INSPECT the flywheel for damage or wear. CARRY OUT a flywheel runout check. INSTALL a new flywheel as necessary. REFER to ENGINE- 3.8L & 3.9L for 3.8L engines or ENGINE- 4.6L (2V) for 4.6L (2V) engines.
Clutch chatter noise - noise when clutch pedal is released at initial takeoff. Clutch is hard to engage and disengage	Pilot bearing worn, damaged or not correctly aligned in bore.	INSPECT the clutch pressure plate release fingers for uneven wear, clutch components burnt or a seized pilot bearing. INSTALL a new pilot bearing as necessary. REFER to CLUTCH .
Clutch vibration	Loose flywheel bolts. Damaged or loose clutch pressure plate Excessive flywheel runout.	Go To PINPOINT TEST I: REAR SUSPENSION NOISE .
Transmission rattling/clattering noise - noise at idle or on light acceleration from a stop. Gear selection difficult	Gearshift lever joint worn or damaged.	INSTALL a new gearshift lever. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Gearshift lever loose.	TIGHTEN the bolts to specification. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Gearshift linkage rods worn or damaged.	CHECK the linkage bushings for wear. INSTALL new linkage rods as necessary. .
Transmission rattling/clattering noise-occurs in neutral or in gear, at idle	Incorrect fluid level or fluid quality.	CHECK that the transmission is filled to the correct level and with the specified fluid. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transmission rattling/clattering noise - noise at idle in neutral	Worn or rough reverse idler gear.	CHECK the reverse idler gear. REPAIR as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Rough running engine, cylinder misfire.	CHECK the ignition system. CARRY OUT a cylinder power test. REFER to ENGINE SYSTEM-GENERAL INFORMATION .
	Excessive backlash in gears	CHECK the gear backlash. ADJUST as necessary. REFER to REAR DRIVE AXLE/DIFFERENTIAL - FORD 7.5" RING GEAR for Ford 7.5 rear axles or REAR DRIVE AXLE/DIFFERENTIAL - FORD 8.8" RING GEAR for Ford 8.8 integral axles.
	Worn countershaft gears.	REPAIR as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transmission whine-a mild whine at extreme speeds or high rpm	Rotating gears/geartrain.	Acceptable noise.
Transmission whine-a high pitched whine, also described as a squeal	Transmission gears are worn (high mileage vehicle).	Result of normal gear wear. REPAIR as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Mismatched gear sets.	INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Damaged or worn transmission bearing.	INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transmission growling/humming-noise occurs in the forward gears. The noise is more prominent when the gear is loaded. The problem gear can be located as the noise occurs in a specific gear position	Gear is cracked, chipped or rough.	INSPECT the transmission gears for damage or wear. INSTALL new gears as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transmission hissing-noise in neutral or in forward gears. As bearings wear or break up, the noise changes to a thumping noise	Damaged or worn bearings.	INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transmission knocking/thudding-noise at low speeds in forward gears	Bearings with damaged balls or rollers or with pitted and spalled races.	INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transmission rumble/growl-noise at higher speeds in forward gears, more pronounced in a coast/deceleration condition	Incorrect driveline angle.	CHECK the driveshaft for damage, missing balance weights or undercoating. Using the vibration analyzer (VA), CHECK the driveshaft balance. CARRY OUT a driveline vibration test. For additional information, REFER to DRIVELINE SYSTEM-GENERAL INFORMATION . REPAIR as necessary.
	Driveshaft out of balance or damaged.	CHECK the driveshaft for damage, missing balance weights or undercoating. Using the vibration analyzer (VA), CHECK the driveshaft balance. CARRY OUT a driveline vibration test. For additional information, REFER to DRIVELINE SYSTEM-GENERAL INFORMATION . REPAIR as necessary.
Transmission rumble/growl-noise at all speeds in forward gears, more pronounced in a heavy acceleration condition	Damaged or worn transmission bearing or gears (high mileage vehicles).	CHECK transmission fluid for excessive metal particles. REPAIR as necessary. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
Transfer case whine-noise at all ranges	Incorrect fluid level or fluid quality.	CHECK that the transfer case is filled to the correct level and with the specified fluid. REFER to MANUAL TRANSAXLE-T50D for T50D transmissions or MANUAL TRANSAXLE-TR3650 for TR3650 transmissions.
	Worn oil pump.	DISASSEMBLE the transfer case. CHECK the oil pump for wear or damage. REPAIR as necessary.
	Under-inflated or oversized tires.	CONFIRM that the tires and wheels are correct for the vehicle. CHECK that the tire inflation pressures are correct.
Transfer case growl/rumble-noise at all ranges (A small amount of planetary noise can be heard when the transfer case is operated in low range.)	Damaged or worn bearings or planetary gear.	DISASSEMBLE the transfer case. CHECK the bearings or planetary gear for wear or damage. REPAIR as necessary.
Transfer case scraping/grating-noise at all ranges	Excessively stretched drive chain hitting the case.	DISASSEMBLE the transfer case. CHECK the drive chain for wear or damage. REPAIR as necessary.
Transfer case howl/hum - noise at all ranges or high range only	Worn or damaged sun (input) gear, clutch pack (intermediate) gear or output shaft gear.	DISASSEMBLE the transfer case. CHECK the gears for wear or damage. REPAIR as necessary.
Transfer case howl/hum - noise at low range only	Worn or damaged intermediate gear and sliding gears (clutch pack).	DISASSEMBLE the transfer case. CHECK the gears for wear or damage. REPAIR as necessary.
Transfer case vibration - vibration felt with vehicle in 4WD	Transfer case mounting. Driveshaft out of balance. Excessive pinion flange runout.	Go To PINPOINT TEST M: TRANSFER CASE VIBRATION .