Symptom Chart - Transmission Operation

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Condition	Possible Sources	Action
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 and bolts 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 . 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 INTRODUCTION - GASOLINE ENGINES article or INTRODUCTION - 6.4L DIESEL ENGINES 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 part for repair procedures. REFER to POWER STEERING article, ENGINE - 5.4L (3V) article, ENGINE - 6.8L (3V) article, ENGINE - 6.4L 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.