00' ZF6, help?

[sniper_101]

I'll keep it short, but need any help possible.

Trans in my truck always shifted a bit rough since I got it this spring. In the last week I noticed it start to grind (worse) going into gear occasionally, and occasionally didn't want to go into gear at all. Today it completely let go on me. Left the farm for town, noticed no shifting problems at all, if anything a bit better than usual but could be wrong. Got to town, and it was rough going into 3rd, fine downshifting into 2nd. Then the next two intersections I had to ram it into 1st to get out of the green light.

I pulled over and I can feel the clutch (either clutch disc itself or clutch cylinder) bottom out about 1" from the firewall. The clutch hasn't disengaged at all, if I crank it over in gear it moves the truck. The pedal does feel a bit soft/spongy, but I haven't drove the truck much lately so I could be wrong, but it does feel strange.
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Any helpful suggestions welcome, as I need it going ASAP.

Thanks guys!

EDIT - I pulled the salve out of the bellhousing and I can push the rod on the slave in and out about 1.5" by hand. Any insight?

[Stroken7.3]

Originally Posted by sniper_101

I'll keep it short, but need any help possible.

Trans in my truck always shifted a bit rough since I got it this spring. In the last week I noticed it start to grind (worse) going into gear occasionally, and occasionally didn't want to go into gear at all. Today it completely let go on me. Left the farm for town, noticed no shifting problems at all, if anything a bit better than usual but could be wrong. Got to town, and it was rough going into 3rd, fine downshifting into 2nd. Then the next two intersections I had to ram it into 1st to get out of the green light.

I pulled over and I can feel the clutch (either clutch disc itself or clutch cylinder) bottom out about 1" from the firewall. The clutch hasn't disengaged at all, if I crank it over in gear it moves the truck. The pedal does feel a bit soft/spongy, but I haven't drove the truck much lately so I could be wrong, but it does feel strange.
-----------------------

Any helpful suggestions welcome, as I need it going ASAP.

Thanks guys!

EDIT - I pulled the salve out of the bellhousing and I can push the rod on the slave in and out about 1.5" by hand. Any insight?

Sounds like it's time for a new prebled masterand slave cylinder assembly. Ford sell that whole assembly.

[sniper_101]

Ford here wants $404 for a pre-bled assembly! I noticed RockAuto has 4x different makers of a pre-bled assembly (probably all the same Chinese company). Are any of these good substitutes? As they're only $100-200, I'd need to order it from Ford and wait anyway.

My current slave has no signs of being bleed-able.

[Toivo]

Mine too just started doing this. I was wondering if it was the clutch, but I will try this route first!

[Toivo]

I think that is about the easiest slave to remove, ever. No tools required. New slave here tomorrow, $46.

[sniper_101]

Let me know how that turns out. I have a full Master/Slave cylinder pre-bled system coming sometime this week.

x2 on the easy removal! Took me all of 10 minutes to remove the entire hydraulic clutch system.

[Jake]

Check the bushings on the pedal assembly first, they tend to wear out and cause some of the exact symptoms you are describing.

[Toivo]

Originally Posted by Jake

Check the bushings on the pedal assembly first, they tend to wear out and cause some of the exact symptoms you are describing.

I just noticed that my bushings are gone 100% when looking to see if I can increase clutch rod travel. I will replace that and possibly get some more travel.

Can the rod travel be increased, or do I need to buy a new pressure plate/throwout bearing?

I'm not hearing any of the typical failing throwout bearing noises or symptoms or any other bad noises than the occasional squeak from the clutch.

Input?

[Jake]

When you replace the bushing everything should be back to normal. What was happening is that your clutch was not disengaging all the way because when you pushed the pedal down, much of the travel was taken up by the slack in the bushing, meaning that it wasn't even putting pressure on the throwout bearing until you were getting close to the floor.

[Toivo]

Im gonna go pop the new slave out quick, see if the shift fork is bent.

Jake, is that bushing aavailable from Ford?