Grabber Posted September 20, 2009 Report Share Posted September 20, 2009 TSB 09-19-11 SHELBY GT500 - CLUTCH DRAG - BUILT BEFORE 9/1/2008 This article supersedes TSB 9-9-2 to update the Service Procedure and Part List ISSUE: Some 2007-2009 Mustang Shelby GT500 vehicles built before 9/1/2008 may exhibit the following clutch/transmission symptoms: hard to disengage or engage 1st and reverse, hard to shift any gear, vehicle creeps with transmission in gear and clutch pedal fully depressed without brake pedal application. These symptoms may be caused by the clutch not disengaging fully when the clutch pedal is fully depressed. This may be due to flywheel distortion caused by excessive heat build-up during unique traffic conditions (example: severe stop/go urban driving, excessive clutch slipping). The clutch system is designed for performance driving conditions. ACTION: Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Located at the end of the procedure are Figures 1, 2 and 3 which show the typical appearance of a flywheel and clutch that has been damaged due to overheating of the clutch. Figures 4, 5 and 6 show the typical appearance of a good flywheel and clutch. This procedure does not apply to or correct the normal characteristics of the twin-disc cera-metallic clutch used in the Shelby GT500 vehicle or normal wear. The twin disc cera-metallic clutch incorporates racing technology to combine a low inertia assembly with a very durable friction material with high torque capability. Depending on your driving technique, the smoothness of how the clutch reacts to clutch engagements may be different from other vehicles that use a single disc clutch system. Also refer to pages 8 and 9 of the GT500 Owner Guide Supplement for additional information. Normal Operating Characteristics Of The Twin Disc Cera-metallic Clutch Clutch chatter/shudder when engaging the clutch. Narrow or abrupt engagement point. Hiss upon clutch engagement or disengagement. Transmission gear rollover noise at idle. Gear rattle noise at very low speeds when in 1st or 2nd gear. Normal wear. Transmission Synchronizer Diagnosis Procedure The following procedure is to be used to determine if the synchronizer assemblies in the transmission may have been damaged by attempting to operate the vehicle with a dragging clutch. 1. Set parking brake. 2. Transmission in neutral. 3. Start engine and allow it to idle. 4. Clutch engaged - pedal fully released. 5. Attempt to shift transmission into first gear by firmly pushing shift lever approximately 5-10 lbf (22-45 N) force for 2-3 seconds. 6. If the synchronizers are okay, the transmission will not make any clash or grinding noise. You will not be able to move the gearshift lever into the selected gear (the synchronizer will block out gear engagement) and the engine RPM will decrease slightly. 7. Repeat the synchronizer test (Step 5 and 6) on all of the other forward gears. a. If the transmission passes the synchronizer test, the transmission will not require additional service; proceed with clutch/flywheel replacement only. Refer to Clutch Replacement procedure. b. If clash/grinding noise is found when performing the synchronizer diagnostic, the transmission will need to be repaired along with the replacement of the clutch. Refer to Transmission Repair procedure. Clutch Replacement 1. Remove the transmission per Workshop Manual (WSM), Section 308-03C. 2. Remove and replace flywheel per WSM, Section 303-01C. Discard old bolts and use bolts provided in flywheel kit. 3. Install new pilot bearing per WSM, Section 308-01. 4. Install new clutch disc and plate assembly per WSM, Section 308-01 (vehicles with solid design flywheel). Discard old bolts and use bolts provided in clutch kit. Tighten bolts to 89 lb-in (10 N-m) in a star pattern. Tighten an additional 90 degrees in a star pattern. 5. Apply a small amount of Motorcraft® PTFE Lubricant to the clutch hub splines per WSM, Section 308-01. 6. Install the transmission per WSM, Section 308-03C. Transmission Repair 1. Remove, drain, disassemble and clean the transmission per WSM, Section 308-03C. 2. Remove and replace input shaft and all synchronizer assemblies per WSM, Section 308-03C. 3. Assemble the transmission per WSM, Section 308-03C. 4. 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-B Transmission Kit XG-8 Motorcraft® PTFE Lubricant XT-5-QM Motorcraft® MERCON® V Automatic Transmission Fluid PM-1-C Motorcraft® High Performance DOT 3 Motor Vehicle Brake Fluid XG-1-C Motorcraft® Premium Long-Life Grease TA-30 Motorcraft® Silicone Gasket and Sealant TA-25 Motorcraft® 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. OPERATION DESCRIPTION TIME 091911A 2007-2009 Mustang GT500: Replace The Clutch Disc And Plate Assembly; Pilot Bearing And Flywheel. Includes Time To Remove And Install Transmission, Perform The Synchronizer Diagnosis (Do Not Use With Any Other Labor Operations) 3.9 Hrs. 091911B 2007-2009 Mustang GT500: Replace The Input Shaft; Synchronizer Assemblies, Clutch Disc And Plate Assembly; Pilot Bearing And Flywheel. Includes Time To Remove And Install Transmission, Perform The Synchronizer Diagnosis (Do Not Use With Any Other Labor Operations) 7.4 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 6375 69 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 © 2009 Ford Motor Company Revised Feb 15th 2010: New TSB has superceded this one. See this thread: This TSB is now out of date and has been replaced with TSB 10-3-8 http://www.teamshelb...__fromsearch__1 Quote Link to comment Share on other sites More sharing options...
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