1996 Bronco/F-Series

Section 08-00: Clutch System, Service

1996 F-150, F-250, F-350, F-Super Duty Chassis Cab and Bronco Equipped with Manual Transmission Workshop Manual

DIAGNOSIS AND TESTING

Pinpoint Tests

PINPOINT TEST A: CLUTCH SLIPPAGE

A1 CHECK FLUID LEVEL

Engine off.
Check the fluid level in the clutch master cylinder.

Is the fluid level full?

Yes	No
GO to A2.	ADD brake fluid and CHECK for leaks in the clutch hydraulic system.

A2 INSPECT CLUTCH PEDAL

Inspect the clutch pedal pivot point for proper lubrication.

Is the clutch pedal pivot point properly lubricated?

Yes	No
GO to A3.	LUBRICATE the clutch pedal pivot point.

A3 INSPECT CLUTCH ASSEMBLY (DISC/PRESSURE PLATE)

Inspect clutch disc for oil or grease.

Is clutch disc contaminated with oil or grease?

Yes	No
CHECK and REPAIR source of grease or oil leak. REPLACE clutch disc. REFER to Section 08-01.	INSPECT clutch disc, clutch pressure plate, and flywheel for wear. REPLACE as necessary. REFER to Section 08-01 for replacement procedures.

PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER

B1 CHECK ENGINE OR TRANSMISSION MOUNTS

Inspect all engine and transmission mounts for looseness. Refer to Section 02-03 if necessary.

Were any engine or transmission mounts loose or damaged?

Yes	No
TIGHTEN or REPLACE the engine or transmission mounts. REFER to Support Insulators in the Removal and Installation portion of Section 02-03.	GO to B2.

B2 INSPECT CLUTCH PRESSURE PLATE

Remove the clutch pressure plate. Refer to Section 08-01.
Inspect the clutch pressure plate and diaphragm springs for wear. Check for warping and discolored surface.

Are there any signs of wear present on the clutch pressure plate?

Yes	No
REPLACE the clutch pressure plate. REFER to Disc and Pressure Plate in the Removal and Installation portion of Section 08-01.	GO to B3.

B3 CHECK CLUTCH DISC

Perform the clutch disc inspection procedure in this section.

Is the clutch disc OK?

Yes	No
INSPECT the flywheel for damage (warpage or discoloring from excessive heat) and CHECK flywheel runout. REFER to the Flywheel Runout Check in the Cleaning and Inspection portion of this section. INSPECT clutch release hub and bearing.	REPLACE the clutch disc.

PINPOINT TEST C: CLUTCH DRAG

C1 CHECK FLUID LEVEL

Engine off.
Inspect the fluid level in the clutch master cylinder reservoir.

Is the fluid level full?

Yes	No
GO to C2.	ADD brake fluid and CHECK for leaks in the clutch hydraulic system.

C2 CHECK DIAPHRAGM SPRING

Remove the transmission. Refer to Section 07-03A and Section 07-03B.
Inspect the clutch pressure plate and diaphragm spring for wear.

Are there any signs of wear to the clutch pressure plate or diaphragm spring?

Yes	No
REPLACE the clutch pressure plate. REFER to Section 08-01.	INSPECT the clutch disc for damage and the flywheel for excessive runout. REPLACE as necessary. REFER to Section 08-01.

PINPOINT TEST D: CLUTCH PEDAL PULSATION

D1 INSPECT CLUTCH PEDAL

Inspect the clutch pedal pivot point for proper lubrication.

Is the clutch pedal pivot point properly lubricated?

Yes	No
GO to D2.	LUBRICATE clutch pedal pivot point (shaft and bushing). REFER to Section 08-02.

D2 CHECK FLYWHEEL RUNOUT

Remove transmission. Inspect flywheel for excessive runout.

Is flywheel runout excessive?

Yes	No
REPLACE as necessary. REFER to Section 08-01.	INSPECT clutch disc for excessive runout.

PINPOINT TEST E: CLUTCH-RELATED VIBRATIONS

E1 CHECK FOR ENGINE COMPONENT GROUNDING

Raise the vehicle on a hoist.
Check the engine mount interlocks for grounding.
Check the exhaust manifold or other engine component grounding on the body or frame.

Is there evidence of grounding on body or frame?

Yes	No
REPAIR the components as necessary.	GO to E2.

E2 CHECK FOR ACCESSORY DRIVE VIBRATIONS

Disconnect the accessory drive belts one at a time and check for vibration.

Does the vibration stop when the drive belts are removed from the engine?

Yes	No
REFER to Section 03-05 to diagnose the accessory drive belt components.	GO to E3.

E3 CHECK FOR RELEASE BEARING NOISE

Start the engine.
Depress and hold clutch pedal.

Is a whirring, grating or grinding noise present?

Yes	No
REPLACE the clutch release hub and bearing. REFER to Section 08-02.	GO to E4.

E4 INSPECT FLYWHEEL

Remove the transmission.
Inspect for loose flywheel bolts.
Perform Flywheel Runout Check in the Cleaning and Inspection portion of this section.

Is the flywheel OK?

Yes	No
GO to E5.	TIGHTEN or REPLACE the flywheel.

E5 CHECK FOR PRESSURE PLATE IMBALANCE

Remove the transmission.
Support the engine securely.
Verify vibration with pressure plate installed.
Operate the engine with the transmission removed.
Remove clutch pressure plate.

Is the vibration still present?

Yes	No
REFER to Section 03-00 to diagnose the engine vibration concern.	REPLACE the clutch pressure plate.

PINPOINT TEST F: HARD SHIFTING

F1 CHECK HIGH SHIFTING EFFORTS

Set parking brake.
With shift control selector in reverse, clutch disengaged and engine idling, move shift lever to a position halfway between reverse and neutral.
Slowly engage clutch.
Gear clash can now be heard if an attempt is made to shift into reverse with clutch engaged, and clutch reserve can now be measured.
While maintaining light pressure on shift selector, slowly press clutch pedal toward the floor. At a point in the travel of the clutch pedal the gear clash will stop and the shift selector will slide easily into reverse position. The amount of travel remaining until the pedal touches the floor is defined as reserve. If pedal is all the way to the floor before stopping gear clash, clutch pedal reserve is not adequate.

Is there adequate clutch pedal reserve?

Yes	No
Clutch system OK.	ADD brake fluid and CHECK for leaks in the clutch system. If OK, GO to F2.

F2 INSPECT CLUTCH DISC AND PRESSURE PLATE

Check clutch disc and clutch pressure plate for wear and warpage.

Is clutch disc and/or clutch pressure plate worn or warped?

Yes	No
REPLACE clutch disc and clutch pressure plate as required. REFER to Section 08-01.	GO to F3.

F3 INSPECT CLUTCH RELEASE HUB AND BEARING

Check for worn or damaged clutch release lever (if equipped).
Check for worn transmission input shaft pilot bearing or clutch release bearing.

Is clutch, transmission input shaft pilot bearing, clutch release lever or clutch release hub and bearing worn or damaged?

Yes	No
REPLACE parts as necessary. REFER to Section 08-01.	CHECK transmission. REFER to Section 07-03A or Section 07-03B.

PINPOINT TEST G: FLUID LEAKAGE

G1 INSPECT CLUTCH FLUID LEVEL

Engine off.
Inspect the fluid level in the clutch master cylinder reservoir.

Is the fluid level full?

Yes	No
CHECK for air in system. RETURN to Symptom Chart.	GO to G2.

G2 INSPECT CLUTCH MASTER CYLINDER

Inspect clutch master cylinder (from underneath dash).
Check all tube connections.
Inspect clutch slave cylinder.

Is clutch hydraulic system leaking?

Yes	No
REPLACE parts as necessary. REFER to Section 08-02 . BLEED system. REFER to bleed procedures in the Adjustments portion of this section.	Clutch hydraulic system OK.

PINPOINT TEST H: EXCESSIVE NOISE

H1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST

Start the engine and let idle.
Depress the clutch pedal.

NOTE: With the clutch pedal fully depressed, the transmission input shaft will stop rotating.

Does the noise stop when the clutch pedal is depressed?

Yes	No
CHECK transmission input shaft pilot bearing. If OK, REFER to Section 07-03A and Section 07-03B to diagnose transmission noise concern.	GO to H2.

H2 CHECK FLUID LEVEL

Check the fluid level in the clutch master cylinder.

Is the fluid level full?

Yes	No
GO to H3.	ADD brake fluid and CHECK clutch hydraulic system for leaks.

H3 CHECK RELEASE HUB AND BEARING

Remove the transmission. Refer to Section 07-03A or Section 07-03B.
Inspect the clutch release hub and bearing for wear or loss of lubrication.

Are there any signs of wear or loss of lubrication?

Yes	No
REPLACE the clutch release hub and bearing. REFER to Section 08-01.	GO to H4.

H4 CHECK TRANSMISSION INPUT SHAFT PILOT BEARING

Inspect the transmission input shaft pilot bearing for damage.

Is the transmission input shaft pilot bearing OK?

Yes	No
GO to H5.	REPLACE the transmission input shaft pilot bearing. REFER to Section 08-01.

H5 CHECK RELEASE LEVER (IF EQUIPPED)

Inspect the clutch release lever for wear or damage.

Are there any signs of wear or damage?

Yes	No
REPLACE the clutch release lever.	GO to H6.

H6 CHECK TORSION SPRING

Inspect the torsion spring for fatigue.

Are there any signs of fatigue?

Yes	No
REPLACE the clutch disc. REFER to Section 08-01.	INSPECT the crankshaft end play. REFER to Section 03-00.