3rd REVISION - The new revised Clutch TSB 09-19-11

[mr ford]

deleted

Edited January 5, 2010 by mr ford

[Grabber]

Article 05-B-2009

Mustang GT500 Normal Operation

2007- 2009 Mustang GT500

 

A review of warranty claims and returned parts has found that some dealers are replacing the clutch assembly for normal operating characteristics of the GT500 clutch assembly.

 

The GT500 Owners Guide, page 8 and 9, describes the normal operating characteristics of the twin disc Cera-Metallic clutch. These are:

 

Clutch chatters/shudder when engaging the clutch.

 

Narrow or abrupt engagement points.

 

Hiss upon clutch engagement or disengagement.

 

Transmission gear roll over noise at idle.

 

Gear rattle noise at very low speeds when in 1st or 2nd gear.

 

Normal wear.

 

Performing repairs on vehicles determined to have normal operation could be considered over repair or misdiagnosis and may be subject to charge back.

 

Category: Powertrain / Manual Transmission

 

Do: Follow TSB 09-09-02 and the Shop Manual when addressing concerns with GT500 clutch and/or transmission shifting issues.

 

Don't: Do not replace the clutch disc if the customer concern matches the normal characteristics described in the Owners Guide.

 

 

[username1]

thumbs down to that news

[stillmy428]

Well my car has been in garage since Dec.1...Dealer has been real nice on the issue.Tech said tranny passed test but they are replacing clutch,flywheel,etc.The mechanic that is doing the work called when he got everything tore down.Flywheel, and clutch looked like they had 50,000 miles on them instead of 3,000.The dealer called just before christmas to let me know they haven't forgot about my car,but Brain the mechanic had lots of time left to use up.So the car sits on a rack all covered up in nice warm garage.Told him not hurry ....Spring will be here soon.So i hope all goes well with job,won't be able to drive it because of this lovely Ohio weather.

[Proctoman]

I just wanted to let my fellow Shelby owners know that I just had the TSB completed at Galpin Ford in North Hills (Los Angeles) CA. I did not even purchase my car from there, and there was not one question asked even about about my mods. The took my car in and returned it in four days without a hitch. Way to go Galpin.

[Boss429]

Anyone from Wisconsin have this repair done? If so, what dealership did you go to and how was the experience?

 

Appreciate the help.

[Boss429]

Anyone from Wisconsin have this repair done? If so, what dealership did you go to and how was the experience?

 

Appreciate the help.

 

 

 

Seriously, no one from WI? Cool, I have the only 07-09 GT500 in WI. Nice!

[bcinu]

Seriously, no one from WI? Cool, I have the only 07-09 GT500 in WI. Nice!

 

 

 

I took my 07 in to Mac Haik Ford here in Houston and they got the TSB done in 2 days and I was out enjoying my convertible in 70 degree temp and blue skies!

This car happens to be one that was traded in because a couple of dealers in the area wouldn't do the TSB. So lucky me had 2518 miles on it.

Edited January 29, 2010 by bcinu

[Grabber]

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

 

 

This TSB is now out of date and has been replaced with TSB 10-3-8

http://www.teamshelby.com/forums/index.php?/topic/53664-4th-revision-the-new-revised-clutch-tsb-10-3-8/page__view__getnewpost__fromsearch__1

[chuckstang]

So when should we be expecting the 5th revision?

 

:jackinbox:

[cobrafan]

Grabber,

 

This is a little scary. I had the tranny replaced when I went in for the TSB in september 2008. Am I still in danger? This was the lastest and greatest at the time.

[Grabber]

Grabber,

 

This is a little scary. I had the tranny replaced when I went in for the TSB in september 2008. Am I still in danger? This was the lastest and greatest at the time.

 

 

Your fine. No worry.

 

The only thing you don't have is a new CSC and since yours is running good....it's OK.

 

Enjoy your car.

[pmustang]

Hello Folks, New poster here, New owner as well. I live in the UK (thus the car is not under ford warrantee so any work is to be paid for by myself or the seller) and have just bought a 2007 Shelby GT500. with sub 5k miles. The day after purchasing the car, owner still had it in his possession, the clutch went out. Reported by owner as a slippage in 5th and 6th gears with the garage (mustang specialist) feeling it is a clutch center plate (or pressure plate?) failure. He did not feel it was the flywheel as there is no judder at all. After speaking with several folks including one of the board members here I have ordered a flywheel as well. Figured it was insurance. The clutch and flywheel are Spec items and hopefully they are well thought of. It has been recommended to me by several threads, TSBs and a board member to change out the pump as well. Can anyone explain why this may be needed? The seller is paying for the R&R of the clutch and for the part itself. As I have chosed to do the flywheel I am paying for this. I don't want to change a pump with sub 5k miles on it unless it is needed. Supposedly it is quite involved to change out the pump? is that corrrect?

 

I am not going to dig into the trans as that has been reported to me by the shop doing the work (and by my test drive) to be working perfectly.

 

I appreciate any advice given.

 

Regards: Peter

[DDT]

So when should we be expecting the 5th revision?

 

:jackinbox:

 

 

When a Load of 2010 Clutches start failing?????????

[Grabber]

Hello Folks, New poster here, New owner as well. I live in the UK (thus the car is not under ford warrantee so any work is to be paid for by myself or the seller) and have just bought a 2007 Shelby GT500. with sub 5k miles. The day after purchasing the car, owner still had it in his possession, the clutch went out. Reported by owner as a slippage in 5th and 6th gears with the garage (mustang specialist) feeling it is a clutch center plate (or pressure plate?) failure. He did not feel it was the flywheel as there is no judder at all. After speaking with several folks including one of the board members here I have ordered a flywheel as well. Figured it was insurance. The clutch and flywheel are Spec items and hopefully they are well thought of. It has been recommended to me by several threads, TSBs and a board member to change out the pump as well. Can anyone explain why this may be needed? The seller is paying for the R&R of the clutch and for the part itself. As I have chosed to do the flywheel I am paying for this. I don't want to change a pump with sub 5k miles on it unless it is needed. Supposedly it is quite involved to change out the pump? is that corrrect?

 

I am not going to dig into the trans as that has been reported to me by the shop doing the work (and by my test drive) to be working perfectly.

 

I appreciate any advice given.

 

Regards: Peter

 

 

Peter,

 

Change out the CSC. It only takes a few minutes and is very inexpensive.

 

[pmustang]

Do you have a ballpark on the price ot that item in the USA? I am paying some steep prices for bits over here in the UK, I don't want to get too abused on this bit. Can't thank you enough for the photo, certainly appears to be much easier than I was thinking.

 

That is obviously sitting behind the flywheel and clutch assembly on the transmission?

 

Just a question, Why would you replace that item when doing a flywhell and clutch, Or is it obviously because its accessible and thus the time to do it?

 

Cheers. peter

[Grabber]

Do you have a ballpark on the price ot that item in the USA? I am paying some steep prices for bits over here in the UK, I don't want to get too abused on this bit. Can't thank you enough for the photo, certainly appears to be much easier than I was thinking.

 

That is obviously sitting behind the flywheel and clutch assembly on the transmission?

 

Just a question, Why would you replace that item when doing a flywhell and clutch, Or is it obviously because its accessible and thus the time to do it?

 

Cheers. peter

 

 

The CSC is under $100 here in the states. Yes it is on the front of the tranny and behind the flywheel and clutch. Here's a better pic of it. Also don't forget to use the teflon lube on the splines of the input shaft after you clean the shaft. Folks are replacing the CSC because it is so cheap and some have had problems. This part is what we used to call the throw out bearing. It makes the clutch work.

 

Edited April 10, 2010 by Grabber

[pmustang]

thanks once again for the photos and info.

 

I have asked the place doing my work how much the pump would be. I would get mighty stung ordering it from the US and shipping it here due to taxes and the broker fees for collecting the taxes. Its hard to determine what will and won't get charged when you ship stuff, I was charged 76 pounds (about 120 US dollars) in taxes and fees just for a sweater my mother sent me! I know, incredible.

 

thx. Peter

[Mustangmike57]

Had TSB work done on transmission about 6 weeks go, great results, fixed the problem. Parked the car for 8 days, got in today, dove it about 100 yards to a stop sign, had to let out the clutch in 1st, I felt a little shutter again. It only did it once, maybe a little rust forming on the clutch?

[jcthorne]

Are the 2007 thru 2009 Ceramic clutches still available or are the only service parts the 2010 organic clutch?

[pmustang]

figured I'd give you guys a report, Since I live in the UK it took quite some time to get the parts, (spec clutch and flywheel and new pump) they tore the car down the other day and the clutch was gone, Reported that normally when clutch is unbolted it pushed off due to the pressure plate exerting pressure on the flywheel, It did not rise off at all (I am only reporting what I remember from the mechanic telling me so I may have it slightly wrong) Said the wear surface of the clutch was all but gone, Said the flywheel was blue. All new spec parts bolted in and hopefully on the road tomorrow. I should have it in my possession in a week or so when me and the seller get together.

 

Question, does this sound right? sub 5k miles and a clutch that is toast? I know the owner drives 2 miles to and from work so plenty of stop and go. Not that you can tell but he did not appear to be a car abuser and has 2 ferraris if he wants to go even faster.

 

 

I just hope the spec clutch and flywheel cure the cause of the problem as the price of repairs here would make your eyes water and I'd like to own the car for a while before spending a huge wodge of cash on it. 9 dollar a gallon petrol is enough pain for me.

 

cheers. Peter

[Grabber]

figured I'd give you guys a report, Since I live in the UK it took quite some time to get the parts, (spec clutch and flywheel and new pump) they tore the car down the other day and the clutch was gone, Reported that normally when clutch is unbolted it pushed off due to the pressure plate exerting pressure on the flywheel, It did not rise off at all (I am only reporting what I remember from the mechanic telling me so I may have it slightly wrong) Said the wear surface of the clutch was all but gone, Said the flywheel was blue. All new spec parts bolted in and hopefully on the road tomorrow. I should have it in my possession in a week or so when me and the seller get together.

 

Question, does this sound right? sub 5k miles and a clutch that is toast? I know the owner drives 2 miles to and from work so plenty of stop and go. Not that you can tell but he did not appear to be a car abuser and has 2 ferraris if he wants to go even faster.

 

 

I just hope the spec clutch and flywheel cure the cause of the problem as the price of repairs here would make your eyes water and I'd like to own the car for a while before spending a huge wodge of cash on it. 9 dollar a gallon petrol is enough pain for me.

 

cheers. Peter

 

 

Peter,

 

5K miles could certainly blue the clutch and toast it. The stop and go driving can really heat it up. It also depends on the driver. What you have stated sounds right to me. I hope your problem is cured now.

Edited June 3, 2010 by Grabber

[Deadly Venom]

My clutch went at 3000 miles. I replaced it with a Spec SS billet twin disc clutch and flywheel. It's rated for 900 lbs of torq. My car is hard to put into reverse sometimes it grinds??? Help! What could cause this?

Thanks Bob

[treeve]

I just wanted to let my fellow Shelby owners know that I just had the TSB completed at Galpin Ford in North Hills (Los Angeles) CA. I did not even purchase my car from there, and there was not one question asked even about about my mods. The took my car in and returned it in four days without a hitch. Way to go Galpin.

 

 

Hi, I saw your posting about Galpin Ford doing the TSB warranty work on your Shelby. I have an '07 GT 500 and contacted them about doing the TSB work. Sounds like they took care of you. Anything that I need to know before I take my car in? Thanks.

[pmustang]

Finally got my car the other day, Has a spec stage 3 flywheel and clutch. Car drives quite well, a bit of judder pulling away and sometimes in reverse, other than that everything seems perfect. I have the old clutch and flywheel and will post photos to show you what 5k miles did to the clutch, there is just about nothing left of the wear faces, Amazing!

 

My skill with the clutch will obviously improve and thus the juddering I am sure will reduce as well.

 

cheers. Peter

[charleslund]

FINALLY GOT MY '08 BACK AFTER HAVING TO WAIT ON THE CLUTCH ASSEMBLY WITH THE '10 SET UP..THE CLUTCH IS MUCH EASIER AND QUIET. IT WAS WELL WORTH THE TIME IT TOOK FOR ALL THE PARTS TO SHOW UP. HAD THE WORK DONE AT HELFMAN FORD (SW HOUSTON) AND EVERY ONE FROM THE ASSISTANT SERVICE MANAGER, THE SERVICE ADVISOR,THE TECH WHO DID THE WORK AND THE CASHIER MADE THE EXPIERENCE MUCH BETTER THAN I HAD ANTICIPATED..

[Bretts08GT500]

Wish I could find a Ford dealership that can replace mine. Called all the Ford service departments within 100 miles of Columbia,SC and no one has a tech that has experience with it. Lugoff Ford initialy said the clutch was ok but when I had others look at it they said it was bad. However, they had no one certified to do this clutch. Lugoff told me to bring it back but I don't want to take it to someone that has never done this work before. Any help? Hell, I will drive to North Carolina if someone knows a good dealership that can complete the clutch right.

[carrera]

What is the difference between flywheel 6375A and flywheel 6375B

[DubbsFaris]

1 letter.

[carrera]

1 letter.