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Revised 2007 - 2009 Clutch Drag TSB 09-09-02


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The Clutch drag TSB has been revised. The verbage has been changed. :headscratch: The PDF file will not post to this site. It's too big so I copied it. Click on the HEADER to make it bigger.

 

 

SHELBY GT500—CLUTCH DRAG—BUILT BEFORE 9/1/2008

 

TSB 09-9-2

 

TSBXPS1.jpg

TSBXPS2.jpg

TSBXPS3.jpg

Edited by Grabber
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The Clutch drag TSB has been revised. The verbage has been changed. :headscratch: The PDF file will not post to this site. It's too big so I copied it.

 

 

SHELBY GT500—CLUTCH DRAG—BUILT BEFORE 9/1/2008

 

TSB 09-9-2

 

FORD:

2007-2009 Mustang

This article supersedes TSB 8-16-4 to add a Normal Operating Characteristics Of The Twin Disc Cera-metallic Clutch.

production fix date, update the Issue Statement and

Service Procedure. • Clutch chatter/shudder when engaging the clutch.

ISSUE • Narrow or abrupt engagement point.

Some 2007-2009 Mustang Shelby GT500 vehicles • Hiss upon clutch engagement or disengagement.

built before 9/1/2008 may exhibit the following • Transmission gear rollover noise at idle.

clutch/transmission symptoms: hard to disengage or • Gear rattle noise at very low speeds when in 1st

engage 1st and reverse, hard to shift any gear, or 2nd gear.

vehicle creeps with transmission in gear and clutch

pedal fully depressed without brake pedal • Normal wear.

application. These symptoms may be caused by the NOTE

clutch not disengaging fully when the clutch pedal is THE GT500 CLUTCH SHOULD BE

fully depressed. This may be due to flywheel DIAGNOSED/REMOVED/REPLACED AS A

distortion caused by excessive heat build-up during COMPLETE ASSEMBLY ONLY. DO NOT TAKE

unique traffic conditions (example: severe stop/go CLUTCH ASSEMBLY APART.

urban driving, excessive clutch slipping). The clutch

system is designed for performance driving 1. Remove, drain, disassemble and clean the

conditions. transmission per Workshop Manual (WSM),

Section 308-03C.

ACTION

Follow the Service Procedure steps to correct the 2. Remove and replace input shaft and all

condition. synchronizer assemblies per WSM, Section

308-03C.

SERVICE PROCEDURE

3. Assemble the transmission per WSM, Section

Located at the end of the procedure are Figures 1, 308-03C.

2 and 3 which show the typical appearance of a

flywheel and clutch that has been damaged due to 4. Remove clutch disc and plate assembly and

overheating of the clutch. Figures 4, 5 and 6 show pilot bearing per WSM, Section 308-01.

the typical appearance of a good flywheel and 5. Remove and replace flywheel per WSM,

clutch. Section 303-01C. Discard old bolts and use

This procedure does not apply to or correct the bolts provided in flywheel kit.

normal characteristics of the twin-disc cera-metallic 6. Install new pilot bearing per WSM, Section

clutch used in the Shelby GT500 vehicle or normal 308-01.

wear. The twin disc cera-metallic clutch incorporates

racing technology to combine a low inertia assembly 7. Install new clutch disc and plate assembly per

with a very durable friction material with high torque online WSM, Section 308-01 (vehicles with solid

capability. Depending on your driving technique, the design flywheel). Discard old bolts and use

smoothness of how the clutch reacts to clutch bolts provided in clutch kit. Tighten bolts to 89

engagements may be different from other vehicles lb-in (10 N•m) in a star pattern. Tighten an

that use a single disc clutch system. Also refer to additional 90 degrees in a star pattern.

pages 8 and 9 of the GT500 Owner Guide

Supplement for additional information.

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do

the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper

vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a

Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation

determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin

(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is

available through Ford Motor Company’s on-line technical resources.

Copyright ã 2009 Ford Motor Company Online Publication Date April 23, 2009 PAGE 1

TSB 09-9-2 (Continued)

8. Apply a small amount of Motorcraftâ PTFE

Lubricant to the clutch hub splines per WSM,

Section 308-01.

9. Install the transmission per WSM, Section

308-03C.

PART NUMBER PART NAME

7R3Z-6375-B Flywheel Kit Includes Bolts

7R3Z-7L596-A Clutch Kit Includes Bolts

7R3Z-7C391-A Trans Kit

XG-8 Motorcraftâ PTFE Lubricant

XT-5-QM Motorcraftâ MERCONâ V Automatic

Transmission Fluid

PM-1-C Motorcraftâ High Performance DOT 3

Motor Vehicle Brake Fluid Figure 1 - Article 09-9-2

XG-1-C Motorcraftâ Premium Long-Life

Grease

TA-30 Motorcraftâ Silicone Gasket and

Sealant

TA-25 Motorcraftâ Threadlock and Sealer

F6ZZ-7600-A Pilot Bearing

1R3Z-7052-AA Transmission Input Shaft Oil Seal

WARRANTY STATUS: Eligible Under Provisions Of

New Vehicle Limited

Warranty Coverage

IMPORTANT: Warranty

coverage limits/policies are

not altered by a TSB.

Warranty coverage limits

are determined by the

identified causal part. Figure 2 - Article 09-9-2

OPERATION DESCRIPTION TIME

090902A 2007-2009 Mustang 7.4 Hrs.

GT500: Replace The Input

Shaft, Synchronizer

Assemblies, Clutch Disc

And Plate Assembly, Pilot

Bearing and Flywheel

Includes Time To Remove

And Install Transmission

(Do Not Use With 7003A,

7003A2, 7003A3, 7003A6,

1007D7, 5212B)

DEALER CODING

CONDITION

BASIC PART NO. CODE Figure 3 - Article 09-9-2

6375 69

PAGE 2

TSB 09-9-2 (Continued)

Figure 4 - Article 09-9-2

Figure 5 - Article 09-9-2

Figure 6 - Article 09-9-2

PAGE 3

Sounds a little confusing and I would guess by the language used they are referring to pictures as well. Is this correct? This information is much more defined than the original tsb and written in more tech type lingo- I found it a bit confusing however it adds up to the same conclusion- but reaches out a little further. Anyone else read anything between the lines?
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The TSB does have Pic's in it. The file is too big for my E-mail to send it on MSN and too big to post the PDF file on here. The pic''s show what a heated flywheel and clutch look like and a normal looking one.

 

They took out the following symptoms from the origianal tsb:

 

"gear grinding during shifts any gear"

 

"clutch slippage in gear with clutch pedal released"

 

"hiss noise with clutch pedal fully depressed(hiss on clutch pedal release is normal for GT500 clutch material)"

 

they also removed the NOTE....

This article applies to vehicles with prior repairs, as well as those with minor modifications, exhibiting above symptoms.

Edited by Grabber
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The TSB does have Pic's in it. The file is too big for my E-mail to send it on MSN and too big to post the PDF file on here. The pic''s show what a heated flywheel and clutch look like and a normal looking one.

 

They took out the following symptoms from the origianal tsb:

 

"gear grinding during shifts any gear"

 

"clutch slippage in gear with clutch pedal released"

 

"hiss noise with clutch pedal fully depressed(hiss on clutch pedal release is normal for GT500 clutch material)"

 

they also removed the NOTE....

This article applies to vehicles with prior repairs, as well as those with minor modifications, exhibiting above symptoms.

 

I have had the TSB done and it has about 800 km on it. 1st to 2nd grinds when cold and stops aft about 10 km? quick shift from 1st to reverse grinds all the time. still chatters sometimes on release.

 

worth taking back to Ford??

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Rob:

 

Does this mean that we should take it back in? I had mine done about 4 months ago. It still hisses when the clutch is fully depressed after driving in the city for a bit.

 

It seems like the "new" flywheel is warped.

 

Any suggestions?

 

Eric

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The TSB does have Pic's in it. The file is too big for my E-mail to send it on MSN and too big to post the PDF file on here. The pic''s show what a heated flywheel and clutch look like and a normal looking one.

 

They took out the following symptoms from the origianal tsb:

 

"gear grinding during shifts any gear"

 

"clutch slippage in gear with clutch pedal released"

 

"hiss noise with clutch pedal fully depressed(hiss on clutch pedal release is normal for GT500 clutch material)"

 

they also removed the NOTE....

This article applies to vehicles with prior repairs, as well as those with minor modifications, exhibiting above symptoms.

 

I think they are starting to want to cut bait with us. My assumption is cars are getting the TSB because of synchro bump(which is normal, even though many on here don't think so...), slipping clutch (which wouldn't be caused by a warped flywheel), and then the one I don't get, the hissing when the clutch pedal is pushed in. They must think that they can get out of fixing cars with only small symptons and too bad when it needs a clutch and flywheel out of warranty.

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Rob, in an earlier thread it was thought that the 2010 GT500 would use an organic clutch. Do you know if that did happen? The new TSB keeps referring to the cera-metallic which I assume is the original OEM material. So if we need a new clutch down the road will we still have the option of getting a ceramic?

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Rob, in an earlier thread it was thought that the 2010 GT500 would use an organic clutch. Do you know if that did happen? The new TSB keeps referring to the cera-metallic which I assume is the original OEM material. So if we need a new clutch down the road will we still have the option of getting a ceramic?

 

Yes the 2010 has a organic clutch.

 

Yes we will be able to keep using the OEM ceramic clutchs in our 2007-2009's.

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This TSB thing just gets stranger and stranger

 

I don't think I am going to brng this new tsb with me when I get my work done, seems like they are just trying to Fuk us more

 

Grabber what are your thoughts on this new release, is it to help us, hurt us or neither lol

 

Personally I think it will make it harder to get the warranty work approved.

 

The problem$ that the prior Ford engineer$ said was a problem$ are now not problem$.

 

 

Read the old TSB and you will see what I mean.

GT500_Clutch_drag_TSB_08_16_04.pdf

GT500_Clutch_drag_TSB_08_16_04.pdf

Edited by Grabber
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CC, are you developing any symptoms, yet?

 

No, but as I picked it up on Nov. 3rd 2006, and it has 16k miles on it (albeit 16k gentle miles) and based on everything I'm reading, I'm nervous and now it sounds as if it will be harder to get Ford to fix it when (if) it breaks :headscratch:

 

but still no symptoms.

CC

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No, but as I picked it up on Nov. 3rd 2006, and it has 16k miles on it (albeit 16k gentle miles) and based on everything I'm reading, I'm nervous and now it sounds as if it will be harder to get Ford to fix it when (if) it breaks :headscratch:

 

but still no symptoms.

CC

 

I understand your nervousness. Perhaps we can discuss further at tomorrows SCBC.

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Personally I think it will make it harder to get the warranty work approved.

 

The problem$ that the prior Ford engineer$ said was a problem$ are now not problem$.

 

 

Read the old TSB and you will see what I mean.

GT500_Clutch_drag_TSB_08_16_04.pdf

I agree. My opinion on the wording is that they feel people are getting clutches replaced that in their opinion don't need to be replaced. Like I have said before, my opinion is that all of the GT500s should have their flywheels fixed, and not just cars with warped flywheels. Clearly Ford doesn't agree, and now are atempting to limit the numbers that get repaired.

 

Once again their behavior reiterates why my Lexus and Acura daily drivers will be replaced with Lexus and Acura daily drivers, because they DO NOT treat their customers like this. Lexus just replaced a radiator at 91K miles for free and gave me an '09 loaner and portered the thing, because they know they had a issue with '04's radiators. This is a 5 year old truck with 91K miles and they fixed it. Ford won't fix something with 36001 miles on it....for that matter they will avoid fixing our cars with what they know are defective design flywheels in every GT500 they build during the time period.

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[quote name='AlloyDropTop' date='May 2 2009, 04:41 PM' post='699008

 

Once again their behavior reiterates why my Lexus and Acura daily drivers will be replaced with Lexus and Acura daily drivers, because they DO NOT treat their customers like this. Lexus just replaced a radiator at 91K miles for free and gave me an '09 loaner and portered the thing, because they know they had a issue with '04's radiators. This is a 5 year old truck with 91K miles and they fixed it. Ford won't fix something with 36001 miles on it....for that matter they will avoid fixing our cars with what they know are defective design flywheels in every GT500 they build during the time period.

 

 

Exactly why I traded my 07 GT500 for a Lexus yesterday. I hope you folks have good luck with your cars. Mine was perfect but also a ticking time bomb and no dealer would do the TSB.

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I am shocked that more have not chimmed in.

 

I think its complete BS

 

Well, heres what I say, beat the bad out of your tranny while under warranty and just tow it there when it breaks!

 

Then they will have no choice but to fix it uner warranty.

 

How would or could Ford deny a warranty claim because they believe it was abused, just curious, seems like its impossible to prove unless it was obviously raced with slicks and stuff

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I think this too is Ford pussyfooting the issue and trying to minimize the problems. With the current economy, Ford seems to further continue to not back the problems that are well known. Complete BS!! So far, I have been able to have 11 friends and Team Shelby members covered by a local dealership, because the local dealerships were giving problems to the owners...

 

Alex

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Chuck,

 

What they will tell you is that they will take it apart and check the wear if you agree to pay for the labor if it's deemed abuse. If you agree...and they find abuse, it's your bill. I know this is not what you wanted to hear....but it happens all the time.

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FWIW as a mechanical engineer I saw it a lot........ Management butts their heads in and over rides the engneers as they start bean counting........Bad deal, but it's life. Just review the official report on the Challenger accident if you need proof. Thiakol's engineers that made the booster segment's o-rings were pleading for them not to launch at the low temperatures that ultimately led to failure. But NASA/management did not want to again delay the launch.

 

We had a problem 30 years ago at a major aircraft manufacturer when I was a young engineer on a passenger jet that is no longer in service. Since I was the first engineer to be contacted by the inspectors I was allowed to sit in on the meetings. It would have cost BIG dollars to go out and make all the aircraft conform to blue print in a critical area that mounted the engines. The error was not caught until we had quite a few jets out there. So the process began, where as it went up the chain my boss bought off on a few thousanths less than the required clearance. My boss's boss allowed a few less and so on. What really bugged me is that the higher it went the less engineering and more management experience the guy had. To the point that the final decision on how much we would allow it to be non compliant was made by a guy that had less engineering experience than my wife's cat. I watched for years as they flew and not a single jet lost an engine due that that flaw-but I held my breath for a lot of years.......... You management types would say if we waited for the engineers to be completely comfortable with things we would still be driving Model Ts since the engineers would never get off the dime and field anything....... ah the dilemas of life.

Edited by SkyPilot
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FWIW as a mechanical engineer I saw it a lot........ Management butts their heads in and over rides the engneers as they start bean counting........Bad deal, but it's life. Just review the official report on the Challenger accident if you need proof. Thiakol's engineers that made the booster segment's o-rings were pleading for them not to launch at the low temperatures that ultimately led to failure. But NASA/management did not want to again delay the launch.

It's life, but some companies do a better job at making smart decisions on obtaining and keeping long term customers. The domestics have been repeatedly failing at this over the past several decades and what is happening to them right now is direct proof...I don't want to be this way, but the way I have been treated by them, the have it comming....

 

I, too, am an ME, and I also see it, but from company to company it can be dramatic. I happen to work with the one company in my field, where the competition is definitly cutting corners. And I sell alot of equipment because of it, to alot of repeat customers. I hope the competion keeps letting the accountants run their business, because as long as the engineers run ours, we will keep kicking thier a$$ in the market.

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This TSB thing just gets stranger and stranger

 

I don't think I am going to brng this new tsb with me when I get my work done, seems like they are just trying to Fuk us more

 

Grabber what are your thoughts on this new release, is it to help us, hurt us or neither lol

Why not just put in a McLeod or Spec clutch in the car? You know the OEM clutch and flywheel is a poorly designed part so why put it back into your car?

 

I had the TSB repair done in February and I regret it now. I know what a high performance clutch should feel like and the piece of crap Ford clutch is far from it. I thought by putting in a new clutch and flywheel it would shift and drive properly. Boy was I wrong on that one. You can have by clutch and flywheel when I yank it out for a McLeod or Spec in a few months.

 

Am I upset at Ford? Not really. They are not the ones that put in the 200+ HP in the car. The OEM clutch is definitely not designed for 600+ torque.

 

Am I going to turn in my GT 500 in for a Lexus as I've read from others on this thread? No way! Clutch and suspension issues aside I just love driving this car. When I bought this car I didn't have any expectation that it was comparable to a ZR1. Let's see ... $45,000 car compared to a $110,000 car. With a few upgrades (see my signature below) I now have a car that now can hang with a ZR1 for a lot less money. Plus, my car turns heads when I'm driving it and no Lexus or Corvette will do that! :happy feet: :happy feet: :happy feet:

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Well, problem is the TSB does not just replace the clutch and flywheel, other parts need to be replaced as well so even if you want to take your own coin and buy a new clutch/flywheel you still will not have all the new upgraded parts.

 

IMO

It is discrimination that Ford thinks some deserve the new upgraded parts while others do not. It is a fact that people who bought an 09 after a certain date have a completely different flywheel and input shaft then what is in my car.

 

All should be replaced under warranty no questions asked.

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Well, problem is the TSB does not just replace the clutch and flywheel, other parts need to be replaced as well so even if you want to take your own coin and buy a new clutch/flywheel you still will not have all the new upgraded parts.

 

IMO

It is discrimination that Ford thinks some deserve the new upgraded parts while others do not. It is a fact that people who bought an 09 after a certain date have a completely different flywheel and input shaft then what is in my car.

 

All should be replaced under warranty no questions asked.

 

Agreed!

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Well, problem is the TSB does not just replace the clutch and flywheel, other parts need to be replaced as well so even if you want to take your own coin and buy a new clutch/flywheel you still will not have all the new upgraded parts.

 

IMO

It is discrimination that Ford thinks some deserve the new upgraded parts while others do not. It is a fact that people who bought an 09 after a certain date have a completely different flywheel and input shaft then what is in my car.

 

All should be replaced under warranty no questions asked.

 

Agree. Ford knows that these flywheels will all warp, giving a significant slipping event, etc..., yet they choose only to fix the cars with the syptoms, meaning apparently people who slip their clutches alot. I don't know how else the flywheel can get warped, other than by generating excess heat, which can only come from slipping. Since my car doesn't do stop and go traffic, and I engage the clutch quickly, I suspect I won't warp the flywheel. The poor second owner someday might not be so lucky, and then it is open up the checkbook time for them.

 

Why can't Ford just do the right thing and replace them all? They spend millions upon millions on advertising and marketing and yet they throw it all away when they piss people like us off. We are the type of people that convince our neighbors, co-workers, family, freinds, etc... all what to drive. Invest a little in those of us that invested a huge amount to own these cars. It will pay off in the long run, I am certain....

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Well, problem is the TSB does not just replace the clutch and flywheel, other parts need to be replaced as well so even if you want to take your own coin and buy a new clutch/flywheel you still will not have all the new upgraded parts.

 

IMO

It is discrimination that Ford thinks some deserve the new upgraded parts while others do not. It is a fact that people who bought an 09 after a certain date have a completely different flywheel and input shaft then what is in my car.

 

All should be replaced under warranty no questions asked.

 

 

Chuck I just got off the phone a few minutes ago with Tasca. I had brought my 07 in last October and had a complete full TSB approved. Problem was I had taken my Shelby off the road for the winter before all the parts came in.

 

Like I said I just got off the phone with service and they have re-opened my job number and re-ordered all the parts again and they believe all the parts to complete it are already in stock. Parts department will send me a notice if and when all the parts are in and we will schedule a date for repair.

 

I don't believe we have anything to worry about with the verbage with the revised TSB at Tasca. A smaller dealership probably, but I don't think Tasca being a performance Shelby dealership has any problems with Ford when it comes to service.

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Well, problem is the TSB does not just replace the clutch and flywheel, other parts need to be replaced as well so even if you want to take your own coin and buy a new clutch/flywheel you still will not have all the new upgraded parts.

 

IMO

It is discrimination that Ford thinks some deserve the new upgraded parts while others do not. It is a fact that people who bought an 09 after a certain date have a completely different flywheel and input shaft then what is in my car.

 

All should be replaced under warranty no questions asked.

The only other part that is revised is the Tranny inputshaft.

 

...and yes you need that replaced !!!!!

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saweeet that is good news

 

I plan to have some work done at Tasca and will mention it to them and see if they will order the parts for me

 

I have now had my tranny stuck in 1st gear temporarily twice and reverse once

 

This is all in the past 2 months and I never had any signs prior so I'm thinking my time is near :(

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