help ruling out major tranny (manual) problem

[erikandelman]

Hello,

I'm wanting to buy a 1995 F250 7.3PS with 5sp manual tranny.

The only problem with the truck is that it's hard to get into reverse: you set it into place, but it grinds when you let off the clutch. The seller said that pushing very hard on the pedal helps, and it did help when I tried, though not enough to be reliable. I came back here yesterday and read a bunch of posts about the pushrod bushing, went back to the truck this morning, and sure enough, the bushing is broken. The joint was slid over a little, toward coming off the ball. However, I could push the joint all the way onto the ball into what looks like it's intended position, which hence pushed in the rod a tiny bit more (less than 1/16")and this would hold for 5-10 pushes on the pedal, but this didn't seem to make much or any difference in getting it into reverse. Pushing the pedal really hard made the biggest difference.

It goes into all the other gears easily, and does NOT come out of any gear including reverse.

I am hoping y'all will agree that the little bit of play created by the broken bushing is the most likely culprit, and not something in the tranny, like synchronizer, etc. Is there a way to adjust the throw of that pushrod?, because it seems just like it's not getting pushed in enough.

What do y'all think?
Thanks,
Erik

[Believer45]

First thing would be to replace the bushing. Ford part number E69Z*7526*A

List July 21, 2005 (last I bought one) was 11.31.

Many have done mods to the area including me. If you get a drill stop that fits over the stub the rod fits onto, trim off the 4 tabs on the end of the bushing and it on with the drill stop it will hold for a long time. Mine has been in place two years so far with no problems.

CLICK HERE to see a pic. If you have looked at yours you can tell what I did in mine.

I did put in a LUK clutch to get rid of the dual mass flywheel and the engagement point is a coupe inches off the floor instead of right at the floor so that helps as well.

Dave / Believer45

[1997fordman]

Erik,

That sounds familiar. My father-in-law has the same problem. If the original clutch went too long, it might have created a flex in the firewall or pedal bracket from pushing so hard. I understand Ford has a kit to repair this. This could be part of, and hopefully for you the whole problem. In his case, the clutch change and other work came too late. The synchronizer and reverse gear are permanently damaged and the local transmission shop won't touch it because the ZF tranny's parts are very expensive and difficult to replace because the tolerances are tight. He's having to put the truck in reverse before he starts it now. If your tranny is damaged and too much to fix, there is a website on ebay that I found a reman unit for about $1000 plus a $500 core.

Ask the guy about the history on the clutch. I have a 97 with same tranny, and my pedal was also stiff. I changed over from the stock dual mass flywheel to a Luk single mass flywheel and clutch kit, and I believe it saved my tranny and firewall, plus I gained a little torque, acceleration, about 1 mpg, and a noiseless flywheel.

Bottom line, check that firewall and replace the clutch with a Luk kit if it hasn't been already and that should be the end of your problems, that is, if you decide to buy the truck.

[NickKent]

Just keep in mind that if the truck has a dual mass flywheel still that you will need to replace the flywheel and the clutch. If a shop is going to do it for you then you could be looking at $1500-$2000 for the switchover.