JT's Tranny TSB-Here we go...

[JTB]

Went to take the car out today and it ground the gears twice trying to engage reverse with the clutch fully depressed. This combined with some missed higher speed 1st to 2nd shifts over the last few weeks made me pick up the phone and call my dealer. The parts have been ordered today, just before noon on April 29th 2009.

I will update this post as the repair progresses.

There is no doubt in my mind that this repair is necessary for all 500's manufactured before Aug/08. I was hoping to avoid it but it is clear that transmissions without this repair will fail.

[Boston Mike]

Originally Posted by JTB Consulting

Went to take the car out today and it ground the gears twice trying to engage reverse with the clutch fully depressed. This combined with some higher speed missed 1st to 2nd shifts over the last few weeks made me pick up the phone and call my dealer. The parts have been ordered today, just before noon on April 29th 2009.

I will update this post as the repair progresses.

There is no doubt in my mind that this repair is necessary for all 500's manufactured before Aug/08. I was hoping to avoid it but it is clear that transmissions without this repair will fail.

Already have your short throw? If not, get them to install it for you. They're available here in the store...................FWIW, a certain person who should be biased towards Shelby parts told me the FRPP is a better shifter. Plus, it's cheaper and you can continue to use your stock stick/handle with it.

[JTB]

Originally Posted by Boston Mike

Already have your short throw? If not, get them to install it for you. They're available here in the store...................FWIW, a certain person who should be biased towards Shelby parts told me the FRPP is a better shifter. Plus, it's cheaper and you can continue to use your stock stick/handle with it.

Thank BM, already have the FRPP short throw in.

They are throwing in my Steeda UCA in for N/C though, when it's up in the air.

[King Cobra]

Originally Posted by JTB Consulting

Went to take the car out today and it ground the gears twice trying to engage reverse with the clutch fully depressed. This combined with some missed higher speed 1st to 2nd shifts over the last few weeks made me pick up the phone and call my dealer. The parts have been ordered today, just before noon on April 29th 2009.

I will update this post as the repair progresses.

There is no doubt in my mind that this repair is necessary for all 500's manufactured before Aug/08. I was hoping to avoid it but it is clear that transmissions without this repair will fail.

Great to hear JT. It's a good feeling to finally get it done and put it behind you. I know it was a relief to me.

[SLB8SNK]

I sent an email to my local dealer, as well cut and pasted the full TSB (thanks JT). He opened it a few hours ago but no response yet. Will be interesting if he agrees to do it, let alone order the parts and stuff in advance. Hoping we both get these done!

[Rags]

Originally Posted by JTB Consulting

Went to take the car out today and it ground the gears twice trying to engage reverse with the clutch fully depressed. This combined with some missed higher speed 1st to 2nd shifts over the last few weeks made me pick up the phone and call my dealer. The parts have been ordered today, just before noon on April 29th 2009.

I will update this post as the repair progrimes.

There is no doubt in my mind that this repair is necessary for all 500's manufactured before Aug/08. I was hoping to avoid it but it is clear that transmissions without this repair will fail.

Good luck with the repair, how many miles on the odometer before you noticed any problems. I'm at 4000 w/o any issues.

[gr8snkbite]

good luck JTB...you'll be much happier....

[JTB]

Originally Posted by Rags

Good luck with the repair, how many miles on the odometer before you noticed any problems. I'm at 4000 w/o any issues.

Thanks!
I missed a shift at around 7000 miles last summer and then had another two more at around 8000 miles (all hard 1st to 2nd), car went away for the winter. I've had it out for a couple of months now. On the weekend I missed two more shifts and today it started grinding when putting it in reverse.

That was enough for me, I picked up the phone. I have 8500 on it now and it is TSB time.

IMO, this TSB should be turned into a recall by Ford, I hate to see guys that only put on a few thousand miles a year and get stuck with a broken tranny years later and no warranty.

[SLB8SNK]

Guys, I got this back from my dealer, how do I respond and what does it mean?:

Dan,

This tsb has been superseded by 09-9-2. look it over and let me know if these are the issues you are having. If so, I can order the parts. As far as the expertise of my techs, I would have to say they are the best in the business. Let me know.

Thanks


FORD:
2007-2009 Mustang


This article supersedes TSB 8-16-4 to add a production fix date, update the Issue Statement and Service Procedure.

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.

NOTE:
THE GT500 CLUTCH SHOULD BE DIAGNOSED/REMOVED/REPLACED AS A COMPLETE ASSEMBLY ONLY. DO NOT TAKE CLUTCH ASSEMBLY APART.


1. Remove, drain, disassemble and clean the transmission per Workshop Manual (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. Remove clutch disc and plate assembly and pilot bearing per WSM, Section 308-01.

5. Remove and replace flywheel per WSM, Section 303-01C. Discard old bolts and use bolts provided in flywheel kit.

6. Install new pilot bearing per WSM, Section 308-01.

7. Install new clutch disc and plate assembly per online 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.

8. Apply a small amount of Motorcraft® PTFE Lubricant to the clutch hub splines per WSM, Section 308-01.

9. Install the transmission per WSM, Section 308-03C.

[GRABBER]

It sounds like Ford has come up with a way to weasle out of repairs and blame it on wear and tear. This will save them some big bucks.

Amazing.

[SLB8SNK]

Originally Posted by GRABBER

It sounds like Ford has come up with a way to weasle out of repairs and blame it on wear and tear. This will save them some big bucks.

Amazing.

Maybe, but was hoping one of our technical guys could tell me "exactly" how to respond as he does say if my car has the issues he will order parts. I will be the guinea pig on this one.

But for the most part, we still all agree this is a MUST have and it will be worth the effort to get done, correct?

[GRABBER]

Originally Posted by SLB8SNK

Maybe, but was hoping one of our technical guys could tell me "exactly" how to respond as he does say if my car has the issues he will order parts. I will be the guinea pig on this one.

But for the most part, we still all agree this is a MUST have and it will be worth the effort to get done, correct?

This is a must have revision to your car so it does not cost you 5.5K later on your own nickle.

Several people have asked me "what should I say to the dealer when I go in and talk to them about my clutch problem?".

This is what I would do.

Go in and be polite, and if the service advisor does not know about the problem, you will have to school him up. (Have the TSB in your back pocket too)

Tell him that you know for a fact that:

1. The first 11 months of GT500 production cars did not get any Teflon lube on the input shaft and clutch hub.

2. Tell him that you know your clutch hub and input shaft have a bunch of surface rust and corrosion on them because the lube never was applied.

3. Tell him that you know that the rusty shaft and clutch hub cause the clutch to not release on time and drag.

4. Tell him that you know that clutch drag causes your syncros to remain loaded with engine torque and that is why your gears grind inbetween shifts.

5. Tell him that you know the transmission input shaft splines have been revised to be a little wider and broached smoother so it will release on time from the clutch hub.

6. Tell him that you know the clutch hub has been revised to be made out of nickle to prevent the clutch hub from rusting.

7. Tell him that you know your flywheel is made out of nodular iron and it does not dissapate the heat very well so it has warped on you and is toasting your clutch and causing your car to have clutch chatter.

8. Tell him that you know the new flywheel is made out of 4100 series steel and is much thicker to take care of the heat dissapation and warpage problem.

[gr8snkbite]

Originally Posted by GRABBER

It sounds like Ford has come up with a way to weasle out of repairs and blame it on wear and tear. This will save them some big bucks.

Amazing.

my thoughts exactly....

so much for the hiss test...

[Boston Mike]

For those of us non-technical types, what is the difference between the two tsb's?

[gr8snkbite]

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.

[gr8snkbite]

what Rob said....their minimizing costs at their end and putting it back on the consumer...not a good move for Ford.

so even with "any" minor mods, if you need this done...your screwed, unless you can revert back to stock....

[JTB]

Originally Posted by Boston Mike

For those of us non-technical types, what is the difference between the two tsb's?

Basically Ford wants a much more in depth inspection prior to the dealer getting the green light to order the parts.

[Boston Mike]

Originally Posted by JTB Consulting

Basically Ford wants a much more in depth inspection prior to the dealer getting the green light to order the parts.

so, since my parts are already sitting at the dealership awaiting my scheduling the service, I'm all set. I have to say, it was a very laborius inspection they put on my car...

[gr8snkbite]

yea..your good...but frankly, i dont see how mods would be a factor to a known engineering design failure...thats total BS, and i believe just an excuse to not complete the repairs....i feel sorry for those that have not done this yet....Ford really screwed the pooch on this change....
i on the other hand got a new tranny, since mine was repaired weeks before the orig tsb came out, but got a replacement "stock" clutch vice the new one. hasnt been an issue thusfar, but, now i dont see it even getting replaced unless i pay for it..

[The Bone]

I had the clutch replaced and the dealer told me that if I don't get on it and stop driving in stop and go traffic than clutch chatter will return. I find if I stat to get chatter then I go out and hammer it a little and then I'm ok.
If Ford wants to stay in business than they may want to rethink this move or they may be like Chrysler. No threat just a observation