Drive line clunk and clutch issue-ZF6 - Ford Powerstroke Diesel Forum
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Old 11-17-2013, 07:45 PM
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Drive line clunk and clutch issue-ZF6

So I think I've got a couple issues on my '01. First issue is the clutch engagement on several situations.

1)Taking off from a stop, sometimes it is smooth and sometimes it bucks around so bad the front end jumps up and down. This can happen in 1st or 2nd gear take offs.

2)When shifting through the gears the clutch will sometimes just dump as I am letting off the pedal. The only thing I can think of is maybe the throw out bearing is getting hung up on the collar it rides on then lets go causing the clutch plate to slam into the flywheel. It is more prevalent on the 5-6 shift as that shift for me takes more time. If I am accelerating faster and shifting quicker in the 2-3-4-5 shifts it doesn't do it as long as I am perfect on the shifts, but if I slow shift it it will.

The Clunk. I've had 3 shops look at the drive line, one is a tranny shop that has worked on other vehicles for me and done a good job, I think they're a competent shop. All have said the u joints are in good shape. One said that Ford rear ends have slop in them which is more noticeable on a std trans vs an auto. Another said that they could check the lash? on the rear end and reset/shim but that could cause the rear end to whine once the "slop" is taken out.

If any one out there has had these issues and has been able to correct them I would greatly appreciate some advice. Thanks.
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Old 11-30-2013, 06:31 AM
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Sounds like your clutch needs replaced. Make sure you take the flywheel off and take it to a shop to have it machined. Most likely it's warped which causes bucking.

Your clunk could be coming from the slip yoke on the driveshaft. Take it off and clean and grease it. While you have it off, grab ahold of the pinion yoke for your rear axle. Try to turn it back and forth. Proper backlash for gears are only a few thousandths of an inch, so you should barely be able to wiggle it. If you can rotate it back and forth a bit, then they will need to be shimmed. Gear whine is caused by gears with too little backlash. If your shop adjusts them properly, they won't whine. You may want to find a different shop.
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