[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

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

[6-Speed]

You sure jumped on that fast - thanks!

[Grabber]

6-Speed, on Sep 19 2009, 08:54 PM, said:

You sure jumped on that fast - thanks!

Yep.

The PDF file is to large to upload to this site so I had to copy and paste the verbage.

[Grabber]

You may be asking - What are the differences?

Well, they are telling the dealer how to test the syncros to see if they are bad. If they are not bad...then they leave the tranny alone and just do the flywheel and the clutch and pilot bearing.

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.

This post has been edited by Grabber: 19 September 2009 - 10:44 PM

[chuckstang]

clutch engaged, fully released

What does that mean?

I want to perform this test myself

[Grabber]

chuckstang, on Sep 20 2009, 05:33 PM, said:

clutch engaged, fully released

What does that mean?

I want to perform this test myself

Start the car.

Leave your foot off the clutch pedal. (it's engaged)

Then do the test by trying to put pressure on the syncros.

Follow the directions in the TSB when doing this. (Don't push too hard and launch the car into your garage by putting it in gear)

[chuckstang]

maybe I will pass, after looking at the test again, too much gray area

It says push firmly and then in the same sentence 5-10ftpounds of force

IMO firmly and only 5-10 should not go in the same sentence, makes no sense to me.

Honestly Id like to launch it off a cliff so I could collect on it in full LOL

[vipereatr]

Ron - any way you can post the contained photos?

Thx

[shelbypowered]

I have no idea how long these tests for a bad clutch- flywheel - syncros will go on but it is getting close to the point where ford must be wondering why someone in engineering picked this system. Grabber works hard to keep us up to date on all the clutch issues and I thank him for that- who I do not thank is the engineer who designed this lousy system- most ruining of syncros are the result of the poor clutch- in the meantime keep up to date on the aftermarket clutch systems and if you can sock a few bucks- I guess quite a few- aside and pick another clutch for your car- Ford has been generous but are they admitting a mistake or standing behind a poor design or both. I know that this is negative thinking but the future for the early gt 500s under the headline clutch will be what aftermarket clutch do I use. When a stock clutch goes out you have to ask yourself was it me or the desgin- ford - Iwould guess- wondered where the problems would arirse when they put five hundred ponies behind our cars- it could be worse as the rest of the drivetrain seems to take the hard hits. That left peddle always leaves me in a worry- My ford tech. and I know each other by first and last name and that may or may not be so good. Thank all of you for posting your results on aftermarket clutches for our car as you are the true pioneirs for our clutchl issues and it is out of pocket expense for you all. I believe going to ford for a free tsb or related issue is just buying time not curing the problem. I wish grabber had more time to look into aftermarket clutches but that might solve the problem and start poor grabber on trying to defend one ovet the other- his staying in a neutral corner and providing valueable information is the best spot he could pick. thanks grabber-

[Spring Lil Cobra]

yea, thanks Rob. I'll test this on mine (even though I had the TSB done) and see how it performs.

[SVTpower]

Anybody remember before this car was released how Ford tested the durability of the powertrain with no less than 500 launches??? Yeah right..........maybe with a special one-off clutch that never saw production

[chuckstang]

I am curious to know how long my original set up would have lasted.

I find it very odd that my car is much worse now after the TSB

Really makes me think its still not the clutch, but the dam retarded Ford techs

I appologize and dont mean to insult but how is it that many out there with the TSB done have no issues and then many people like me with many

[shelby001]

Grabber, on Sep 20 2009, 08:37 PM, said:

Start the car.

Leave your foot off the clutch pedal. (it's engaged)

Then do the test by trying to put pressure on the syncros.

Follow the directions in the TSB when doing this. (Don't push too hard and launch the car into your garage by putting it in gear)

I suggest doing this test in a empty parking lot.

[Grabber]

shelby001, on Sep 21 2009, 05:41 PM, said:

I suggest doing this test in a empty parking lot.

Agreed.

[SicShelby]

I think the pilot bearing has been added as a replacement as well, is that right Rob? I don't remember that being a part of the TSB when they replaced mine...

Glad they put that in there.

[Grabber]

SicShelby, on Sep 21 2009, 06:33 PM, said:

I think the pilot bearing has been added as a replacement as well, is that right Rob? I don't remember that being a part of the TSB when they replaced mine...

Glad they put that in there.

The Pilot bearing was in the Rev. 2 TSB.

http://www.teamshelb...p...st&p=697699

The photos are in that linky too. They did not change those.

[cutter]

chuckstang, on Sep 21 2009, 07:30 PM, said:

I am curious to know how long my original set up would have lasted.

I find it very odd that my car is much worse now after the TSB

Really makes me think its still not the clutch, but the dam retarded Ford techs

I appologize and dont mean to insult but how is it that many out there with the TSB done have no issues and then many people like me with many

I just got the call that mine is done....but it grinds alittle going into first....WTF..this is from the tech guy,,,I haven't even driven it yet....

Got another call today...Ford Rep. tested it and said tear it back down......

This post has been edited by cutter: 23 September 2009 - 04:37 PM

[COBRA CRUIZER]

Had the flywheel,clutch disc and the pressure plate with all the hardware replaced today!

[Grabber]

cutter, on Sep 22 2009, 11:38 AM, said:

I just got the call that mine is done....but it grinds alittle going into first....WTF..this is from the tech guy,,,I haven't even driven it yet....

Got another call today...Ford Rep. tested it and said tear it back down......

Are they doing the tranny syncro and input shaft replacement on yours too?

Cutter, I hope they get it right this time.

Do you still have both your 500's ?

[2kmelat]

i had the tsb done and it went out after only 3 mounth. every clutch pad is chiping around the edges.