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Symptom Chart - Clutch And Transmission Operation

WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford F550 Super Duty, and 2002 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
CLUTCH AND TRANSMISSION OPERATION SYMPTOM

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.
  • 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.
  • 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.
  • 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 . 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 . CHECK the flywheel runout. REFER to FLYWHEEL RUNOUT CHECK . 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.
  • Hard shifting
  • Insufficient clutch hydraulic system fluid.
  • Clutch hydraulic system fluid leakage.
  • Air in clutch hydraulic system.
  • Clutch not releasing.
  • Transmission concern.
  • 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 to CLUTCH . INSPECT the clutch disc for damage. REFER to CLUTCH DISC CHECK . INSPECT the transmission input shaft pilot bearing for wear and damage. REFER to PILOT BEARING CHECK . CHECK the crankshaft end play. Refer to the appropriate article in ENGINE 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 TRANSMISSION - ZF 6-SPEED .
  • 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 TRANSMISSION - ZF 6-SPEED .
  • Bearings/gears worn/damaged.
  • INSPECT the bearings, the gears, and the gear teeth for wear and damage. REPAIR as necessary. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • 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 TRANSMISSION - ZF 6-SPEED .
  • Engine idle speed too high.
  • REFER to appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
  • Transmission jumps out of gear
  • Gearshift lever boot installed incorrectly.
  • CHECK gearshift lever boot installation. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • Bolts retaining transmission to engine loose.
  • TIGHTEN the bolts to specification. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • Transmission input shaft pilot bearing.
  • INSTALL a new transmission input shaft pilot bearing. REFER to CLUTCH .
  • Axial clearance incorrect.
  • CHECK axial clearance.
  • Internal components damaged.
  • 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 TRANSMISSION - ZF 6-SPEED .
  • Gear teeth worn/damaged.
  • INSPECT, and REPAIR as necessary. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • 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 TRANSMISSION - ZF 6-SPEED .
  • 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 TRANSMISSION - ZF 6-SPEED .
  • 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 . REFER to POWER STEERING , ENGINE 5.4L , ENGINE 6.8L , ENGINE 7.3L DIESEL , CLUTCH CONTROLS or MANUAL TRANSMISSION - ZF 6-SPEED .
  • Input shaft bearing retainer seal.
  • INSPECT, and REPAIR as necessary. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • Shift rail detent plug.
  • INSPECT, and REPAIR as necessary. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • Top cover gasket.
  • INSPECT and REPAIR as necessary. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • Power take-off (PTO) cover.
  • INSPECT, and REPAIR as necessary. INSTALL a new gasket. TIGHTEN to specification. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • Sand holes/cracks in case.
  • INSPECT, and INSTALL a new case as necessary. REFER to MANUAL TRANSMISSION - ZF 6-SPEED .
  • 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 TRANSMISSION - ZF 6-SPEED .
  • Noise occurs during transfer case operation
  • 4x4 system.
  • REFER to FOUR WHEEL DRIVE SYSTEMS for diagnosis and testing procedures.
  • Transfer case jumps out of gear
  • 4x4 system.
  • REFER to FOUR WHEEL DRIVE SYSTEMS for diagnosis and testing procedures.
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