My Transmission & Clutch & Flywheel installation

[06ragtopGT]

My clutch was hanging up more with lower miles (hiss continued a couple of seconds when pedal to the floor). I didnt know that was bad. I would be blocked out of gear every once in a while. Doesnt seem to be doing this in a while. Just now my 1st-3rd shifts are more crunchy.

 

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Does driving the car help the unlubed rusty metal on metal break in?

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If serviced and I find Im all rusty inside like yours Rob do you just clean it up and re lube? Yikes!

Will the clutch show any different specific wear? What other damage could be happening during my 12000 miles?

 

 

Great info Rob! Thanks. :beerchug:

[Grabber]

My clutch was hanging up more with lower miles (hiss continued a couple of seconds when pedal to the floor). I didnt know that was bad. I would be blocked out of gear every once in a while. Doesnt seem to be doing this in a while. Just now my 1st-3rd shifts are more crunchy.

 

-

Does driving the car help the unlubed rusty metal on metal break in?

-

If serviced and I find Im all rusty inside like yours Rob do you just clean it up and re lube? Yikes!

Will the clutch show any different specific wear? What other damage could be happening during my 12000 miles?

 

 

Great info Rob! Thanks. :beerchug:

Once you have the problem, I think you have it for good. However I am no expert or an engineer. There is no written procedure from Ford to clean and lube the shaft. Maybe there will be soon. I don't know. For now they are replacing the tranny and clutch and inspecting the flywheel if you have problems. As for damage happening. I suspect syncro damage for sure.

[SLB8SNK]

Good news is I suspect this or anything related, will fall within the warranty! Right?

[Grabber]

Good news is I suspect this or anything related, will fall within the warranty! Right?

As long as it falls with in the warranty guidelines, then Yes we should be covered. They covered me and many others too. :happy feet:

[Grabber]

The streets dried up this afternoon so I took my GT500 out on test drive to see how the new tranny and clutch would preform. First thing I did was start it up and preform the "Grabber" clutch test in the shop. Did it 3 times.

 

Results: No hissing in nuetral with the clutch depressed to the floor. :happy feet:

 

I let her warm up a minute and then idled out of the neighborhood. As I shifted into 2nd while I drove like a grandma, I noticed no bumpity bump of my syncros like it used to do.

 

I drove into town to return some videos. Just a mellow drive. I got on the Highway for 5 miles and paid attention to all the gears. I got stopped at a couple lights on the way. As I waited for the lights to turn Green I sat in my car with the brake on and the car in nuetral. When the light turned Green, I pushed the clutch in and put it into 1st gear. It went right in IMMEDIATELY. :happy feet: My car used to bump the syncros when putting it in gear unless I would wait 2-3 seconds for the clutch to dissengage.

 

As I shifted from 1st to 2nd.....I took note of how easy the car went into 2nd gear. Then 3rd gear. Smooth driving. 4th, 5th & 6th preformed well too. After returning the videos, I went for a short drive in the hills and then to the gas station, and then home.

 

When I got home, I sat in the car while it idled. Did the clutch test again. Listened. I then popped the hood and listened under the hood. No strange noises are coming from my car. :happy feet:

 

I now have about 40 miles on my new clutch, flywheel and Tranny with Teflon lube on the splines. The biggest difference is this:

 

1. The car goes into 1st gear and reverse as soon as I want it to. No delays.

2. When I shift into 2nd gear, it goes in right away. It's like a silent click that I feel in my hand.

3. 3rd gear is now smooth.

4. 4th, 5th & 6th seem to be nicer.

 

I detailed her again and snapped some photos to show her off. This is an awesome car.

Edited January 21, 2008 by Grabber

[mustang crazy]

The streets dried up this afternoon so I took my GT500 out on test drive to see how the new tranny and clutch would preform. First thing I did was start it up and preform the "Grabber" clutch test in the shop. Did it 3 times.

 

Results: No hissing in nuetral with the clutch depressed to the floor. :happy feet:

 

I let her warm up a minute and then idled out of the neighborhood. As I shifted into 2nd while I drove like a grandma, I noticed no bumpity bump of my syncros like it used to do.

 

I drove into town to return some videos. Just a mellow drive. I got on the Highway for 5 miles and paid attention to all the gears. I got stopped at a couple lights on the way. As I waited for the lights to turn Green I sat in my car with the brake on and the car in nuetral. When the light turned Green, I pushed the clutch in and put it into 1st gear. It went right in IMMEDIATELY. :happy feet: My car used to bump the syncros when putting it in gear unless I would wait 2-3 seconds for the clutch to dissengage.

 

As I shifted from 1st to 2nd.....I took note of how easy the car went into 2nd gear. Then 3rd gear. Smooth driving. 4th, 5th & 6th preformed well too. After returning the videos, I went for a short drive in the hills and then to the gas station, and then home.

 

When I got home, I sat in the car while it idled. Did the clutch test again. Listened. I then popped the hood and listened under the hood. No strange noises are coming from my car. :happy feet:

 

I now have about 40 miles on my new clutch, flywheel and Tranny with Teflon lube on the splines. The biggest difference is this:

 

1. The car goes into 1st gear and reverse as soon as I want it to. No delays.

2. When I shift into 2nd gear, it goes in right away. It's like a silent click that I feel in my hand.

3. 3rd gear is now smooth.

4. 4th, 5th & 6th seem to be nicer.

 

I detailed her again and snapped some photos to show her off. This is an awesome car.

Cool I am glad your car is rolling again.I took mind for a ride today very cool down south that supercharger like that cool air what and awesome car!!!!!

[Grabber]

Today I sent this to the President of my Dealership that did my work.

 

 

TITLE: Excellent Service work on my Shelby GT500

To: Mr. Jon Creedon – President of Vancouver Ford

 

Hi John,

 

I wanted to tell you about my excellent all around experience that I had during the replacement of the transmission, clutch and flywheel on my 2007 SHELBY GT500 last Wed. 1/16/08. My service advisor Rob Prentice worked diligently with FMCO to make sure all the right new and improved parts would be supplied. He also helped get the new installation spec's implemented to make my installation correct. Your parts assistant manager Gary Russell tracked the delivery of the parts for me during the last 2 months. These guys went above and beyond in customer service to keep me updated on the availability of the new parts that I was waiting for. Phone calls and e-mails were always returned and followed up on.

 

Your Senior Master Tech. that did my installation is Dan Robertson. He is a true craftsman in his trade. I watched him work from the outside of the service bay thru the window in the roll up door during part of the installation. He was very careful with my car and did the installation very well. The removal and installation of a transmission in a SHELBY GT500 is no easy task. It’s a tight fit and he did the work with out scratching the underside of the car body or denting the heat shields. My car now runs and shifts great. He is a true professional. I will be requesting to have Dan do all my future work on my cars.

 

My SHELBY GT500 is a truly awesome car. I have a passion for SHELBY's and Mustangs in general. They are more than just a car to me. They are a hobby and I belong to a huge SHELBY club called Team Shelby. In fact my wife and I went to Carroll Shelby’s 85th Birthday party in Las Vegas Friday night 1-11-08 and watched Mark fields give him the first 2008 GT500KR (King of the Road). Your Master Tech. could tell how important this car is to me and made me feel totally comfortable working on it.

 

I just thought you should know how good your team is.

 

Sincerely,

 

Rob

 

 

cc.

Ford /SVT Vehicle Engineering

management.

Edited January 22, 2008 by Grabber

[cobraracing]

Congrats Grabber, I am glad it worked out for you

Your deep investigation into the clutch & tranny woes will help all of us

[Grabber]

Congrats Grabber, I am glad it worked out for you

Your deep investigation into the clutch & tranny woes will help all of us

Thanks.

 

I am very happy with the results. My install went flawless. Not a ding or nick anywhere on my car. My Corsa exhaust tips are much straighter than before too. :happy feet:

[Grabber]

Side views of the new tranny.

 

 

As soon as my new Ford Racing Parts KR shifter comes in, this factory shifter will get swapped out by my master Tech. I wish I would of had the new shifter last week, but oh well.

[Grabber]

My new FRP KR shifter came in today. :happy feet: Now if the weather would just clear up, I could take my car in and have Dan install it.

[Grabber]

I just noticed that the rubber pad on my factory one is not present on my new one. See the rubber pad on the factory one.

 

It's not on the new one ? I need to go back out to the shop and look at it.

[COBRA CRUIZER]

Grabber, I just ordered my FRPP short shifter today. We should be installing it sometime next week.

[Grabber]

I wonder why my brand new shifter just has a metal plate with no big rubber pad on it like the factory one ?

 

Look back at my factory photo and you will see.

 

Anyone else got theres to compare ?

 

Heres mine. Look at the bare plate.

 

Edited January 31, 2008 by Grabber

[COBRA CRUIZER]

I'll let you know in a couple of days, as soon as it arrives. I sort of doubt that it comes with a rubber pad. I guess we can try to transfer the old one.

[COBRA CRUIZER]

I'll let you know in a couple of days, as soon as it arrives. I sort of doubt that it comes with a rubber pad. I guess we can try to transfer the old one.

[Grabber]

I'll let you know in a couple of days, as soon as it arrives. I sort of doubt that it comes with a rubber pad. I guess we can try to transfer the old one.

I was going to have The Master Tech at my dealer install mine. Glue takes time to set up. If I need a bumper, I want to glue it on before I take my car in. If you look at the photo of my existing shifter, you will see a green paint mark for quality control making sure it is secure. I need to find out if this is a factory FRP parts mistake or not. BTW, let me know if yours came with any instructions. Mine did not, so I have no clue if this is normal or not.

Edited January 31, 2008 by Grabber

[Grabber]

I'll let you know in a couple of days, as soon as it arrives. I sort of doubt that it comes with a rubber pad. I guess we can try to transfer the old one.

Let's see what Evo has to say. I asked them and PM'd them with a link to this thread:

 

http://forum.teamshelby.com/forums/index.p...c=24119&hl=

[tispco]

Grabber --

 

I checked the FRPP website and it looks like the shifter does not come with that rubber bumper. I would just transfer the one from your old shifter over to the new one. I have installed aftermarket shifters on a few different cars and typically there is at least a few pieces you have to reuse. Attached is a picture of your shifter from the FRPP website.

[Grabber]

Grabber --

 

I checked the FRPP website and it looks like the shifter does not come with that rubber bumper. I would just transfer the one from your old shifter over to the new one. I have installed aftermarket shifters on a few different cars and typically there is at least a few pieces you have to reuse. Attached is a picture of your shifter from the FRPP website.

That same website has a very good instruction sheet 7 pages long. Very detailed. Nothing mentions the bumper. I need to talk to someone that has installed one.

 

Instructions:

http://www.fordracingparts.com/download/in...ShtM-7210-B.pdf

[billf65]

My Senior Master Technician that installed my new FLYWHEEL, CLUTCH, & TRANSMISSION did a great job. My car was in a bay that was next to a roll up door that had a window in it from the outside, so I was able to watch the entire removal and installation. With a escort I was allowed in the service bay a few times to look things over.

 

My Tech. did the entire job himself except for lifting the transmission and adjusting the exhaust. Now I know why they call him a Master. He has worked there for 12 years. A true professional.

 

Here are a few tips that I have picked up on.

1.) The front of the motor has to be jacked up to get the proper angle to remove and install the tranny. If you have a carbon Fibre intake, it will need to come off so you don’t damage it, or remove the tower brace.

 

2.) Make sure you have the right flywheel before you start the job. Mine was for a GT and I had to get a GT500 one overnighter.

 

3.) After installation, the clutch hydrolics need to be blead off. My tech used a suction machine to get the air out.

 

4.) The Teflon lube gets applied to both Clutch splines and Tranny input shaft.

 

REMOVAL of the Transmission

It took 1 hour and 45 minutes for a master tech to get the tranny out. I watched him do it. These are the steps I watched.

 

1. Remove shifter.

2. Remove my JLT Carbon fibre tube & filter so it would not get damaged during jacking of the motor.

3. Remove front X pipe and Cat's. Temp support rear exhaust and sensor wiring.

4. Remove drive shaft.

5. Remove lower front suspension A arm steel tube brace.

6. Remove tranny X member.

7. Remove tranny.

8. Remove flywheel.

 

INSTALLATION of the new flywheel, clutch and transmission.

The installation of the new parts took 1 hour and 50 minutes. Then you will be ready for a test drive. These are the steps I watched.

 

1.) Install Flywheel.

2.) Install Clutch.

3.) Apply Teflon lube to splines

4.) Install Transmission and shifter.

5.) Install Transmission X support.

6.) install lower front A arm tube brace.

7.) Install Driveline.

8.) Install Front Cats and X pipe exhaust.

9.) Adjust rear exhaust tips.

10.) Hook up electrical sensors to transmission and Cats.

11.) Install stick shift handle and boot.

12.) Bleed air out of clutch hydrolics.

13.) Test Drive

 

 

By the time you check the car in and then the work is done and you do a test drive and then do the paperwork, it turns out to be a 6 hour job. I have some videos and Pic’s coming up that show some of the work.

 

Let me tell you that the car shifts like a different car. No hissing when the clutch is in nuetral and pushed in to the floor. No bumping of the syncros. Smooth shifting and down shifting. Now when I push the clutch in and put it in gear…it goes in right away. I can even down shift into 1st gear at a slow roll from 2nd. It is sweet. To describe the shifting is hard to do in words. It just goes into gear. You feel the click in the gearshift, you do not hear it. Not realy a click, but it feels like the syncros are open and ready to accept the gear. A true pleasure. Yes…a big difference. I also noticed that 4th 5th and 6th are smoother now too. :happy feet:

 

Edit: Torque Spec for new clutch bolts added and Parts Pic.

torque the clutch bolts to 74 in-lb in a star pattern and then double click to 80 in-lb and NO 90* TURN!!

Grabber the clutch part number in the picture is different than the one in the Hotline recommendation. Do you know which is correct?

Thanking you in advance for all the great info.

[Grabber]

Grabber the clutch part number in the picture is different than the one in the Hotline recommendation. Do you know which is correct?

Thanking you in advance for all the great info.

Bill,

The clutch that I have will not be available untill late March or April, that is why it is different. The number on the hotline info is the current clutch, and it is a good product. It is made in Italy. Very expensive.

[billf65]

Bill,

The clutch that I have will not be available untill late March or April, that is why it is different. The number on the hotline info is the current clutch, and it is a good product. It is made in Italy. Very expensive.

I want the nickel plated one. Suspect the hotline unit is not correct?

 

My early build 08 (July 07) has the hanging clutch. Hissing for several seconds after clutch is at the floor in nuetral. This seems to indicate the problem is more than just the lube. (2700 milles)

 

IMO you need the nickel plated clutch, upgraded trans, lube and possibly the flywheel.

 

How did you get the clutch?

 

Read my post in the 2008 Clutch and Tranny thread for my other symptoms. I just did the hiss test tonight and it failed as indicated above.

[LuckySnake]

I want the nickel plated one. Suspect the hotline unit is not correct?

 

My early build 08 (July 07) has the hanging clutch. Hissing for several seconds after clutch is at the floor in nuetral. This seems to indicate the problem is more than just the lube. (2700 milles)

 

IMO you need the nickel plated clutch, upgraded trans, lube and possibly the flywheel.

 

How did you get the clutch?

 

Read my post in the 2008 Clutch and Tranny thread for my other symptoms. I just did the hiss test tonight and it failed as indicated above.

Sounds like your transmission input shaft had damage before install or was damaged during, causing the same symptoms as lack of lube. Maintenance manual warns of such damage causing these symptoms.

Edited February 1, 2008 by LuckySnake

[Grabber]

I want the nickel plated one. Suspect the hotline unit is not correct?

 

My early build 08 (July 07) has the hanging clutch. Hissing for several seconds after clutch is at the floor in nuetral. This seems to indicate the problem is more than just the lube. (2700 milles)

 

IMO you need the nickel plated clutch, upgraded trans, lube and possibly the flywheel.

 

How did you get the clutch?

 

Read my post in the 2008 Clutch and Tranny thread for my other symptoms. I just did the hiss test tonight and it failed as indicated above.

The clutch # in the hotline is correct. I know 4 people that had it put in recently. Sorry you are having problems. Take the car in and have your dealer look at it and verify that it is having problems. If you do have a problem, they will address it. The clutchs are made in Italy and the nickle hub one is in production. It's not released, so if you must have it, then you will need to wait, like I said.

[billf65]

Sounds like your transmission input shaft had damage before install or was damaged during, causing the same symptoms as lack of lube. Maintenance manual warns of such damage causing these symptoms.

This is a possibility. But the only way to find out is a tear down and to me it makes no sense not to put in the nickel hub unit. I am curious to see if there is visible damage or lack of lube and Ford should be too. Put me in coach I want to test the new nickel hub clutch design/upgraded Tranny. I drive this car often and the way a performance car is meant to be driven. Additionally I am very sensitive to how my car reacts.

 

IMO I feel this is not a damage issue but a design issue. I will not go into all the theories that give me this outlook. The bottom line is I will not do this repair without the new clutch. Only time will tell if it is a damage issue or not.

 

I also feel a nickel plated shaft on the tranny is a better way to go with this clutch design. But I also understand why it may be difficult for Ford to make this happen. So I will accept the polished shaft, tolerance change and lube/protectant.

 

Thanks for the info from the maintenance manual.

[billf65]

The clutch # in the hotline is correct. I know 4 people that had it put in recently. Sorry you are having problems. Take the car in and have your dealer look at it and verify that it is having problems. If you do have a problem, they will address it. The clutchs are made in Italy and the nickle hub one is in production. It's not released, so if you must have it, then you will need to wait, like I said.

Dealer will be no problem. The problem will be waiting on Ford/Valeo for the nickel hub clutch for who knows how long. I am familiar with Valeo clutchs both OEM & Racing.

Thanks again for all the great information.

[Grabber]

The problem will be waiting on Ford/Valeo for the nickel hub clutch for who knows how long.

This won't be a problem. When March or April arrives....it will be available.

[KCMO-GT500]

This won't be a problem. When March or April arrives....it will be available.

 

 

I thought it might be may, do you have new info rob?

[HSURB]

I thought it might be may, do you have new info rob?

 

 

Should I start a "KCMO's Transmission and Clutch Install" thread?

 

HSURB