Posted by Kevin (FL) on August 04, 2008 at 06:08:33 from (65.0.132.58):
Well, we dropped the ZF 6 speed + transfer case over the weekend to investigate all the clutch problems we've been having.
Here's what we discovered:
1) Clutch fork had dropped down on top of the collar around the input shaft, large hole worn through the collar at 12 o'clock position. The hole in the top of the collar was about 1 1/2" square.
2) When the clutch fork dropped, it got snagged by the rotating pressure plate and the fork impacted the bell housing and broke out a chunk of aluminum right at the corner where the slave cylinder mounts.
3) The throwout bearing was shot.
4) The roller-bearing pilot "bushing" was dry and most of the needle bearings were gone.
5) The "fingers" on the pressure plate were worn down to nothing and several were completely worn through.
I think that covers the damaged stuff. The only parts that still look good--the flywheel & the clutch itself.
Now I have to drive into town to see if Ford dealer has the piece-of-junk (all plastic) master-slave cyliner assembly and also the collar that mounts over the input shaft to replace the damaged one.
'95 Suburban diesel update--Chevy dealer in Alabama wanted $3300 to R&R injection pump. Had it towed out of there to a diesel shop in town--about $1200 and this includes the remote-mounted PMD with heat sink.
It's tough when both of your work vehicles go down at the same time. As my dad used to say--"Never mind the mule, load the wagon".....
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