[Chewbacca]

Had my 3rd flywheel failure at 96K and waited until my 4R100 acted up before adressing it (luckily got both covered under Geico warranty). Anyone else have a flywheel failure? How many miles?

Symptom was the loud rattling sound at idle or when off accelerator pedal (sounds like a chunck of sheet metal is loosely bolted to engine block, gets lots of attention from anyone in earshot). I have the last 2 flywheels and both sheared right around the crank mouting bolts in a circular fashion. Since the failures have been so simlar, I am wondering if others have had this problem (or did they revise the flywheel in 2000) or if I have a 'hot' starter?

Also want to hear about any aftermarket options since I'll be out of warranty soon and need to plan ahead, assuming this trend will continue.

THANKS AS ALWAYS FOR YOUR INSIGHT!!!
Ty

 

[skidoox]

If you have the automatic trans, the flywheel is called a Flexplate.
I am on my third one at 104,000 miles. I should get my truck back from the shop Wednesday. The first one went at 76,000 miles the next one went at 97,000 miles and the last one went at 104,000 miles. The time between failure is getting shorter. There is a TBS for the problem and it says that all the parts need to be replace along with the flexplate. The flexplate is on nation wide back order, they found mine in Wisconsin. I could not find a aftermarket replacement.
Sorry I am not much help. I am think about get a new truck if they cannot find what is causing the problem with the flexplate. I need a truck I can trust to get me home.

94-99 PowerStroke with auto trans flexplate (flywheel) cracking:
This may occur on some vehicles. When replacing, inspect the flywheel reinforcement plate (F4TZ-6A366-A) and the crankcase spacer (F81Z-6A366-AA) for damage or galling and replace as necessary. Also replace the engine spacer (F4TZ-6A369-A).

 

[Chewbacca]

Skidoox,

Thanks for the sanity check! Have you had the TSB performed on your rig or is it planned for this repair? When you get the truck back could you please send a reply with all the parts they replaced?

Do you know anyplace on-line where I could find this TSB? I think I need to have yet another stern talk with the dealership that sold the truck and has performed the majority of the service in order to hopefully correct this once and for all.

THANKS AGAIN!!!
Ty

 

[skidoox]

Ty

The TBS # is 99-23-6
I found it at this link

TBS site http://www.diesel-central.com/Tech/ford/docs/99-23-6.doc

The sad thing is I had all the parts that the TBS says to replaced, replaced last time and it did not help.

I hope you have better luck than I have had.

TBS 99-23-6



FORD:
1994-97 F SUPER DUTY, F-250 HD, F-350
1994-99 ECONOLINE
1999 SUPER DUTY F SERIES

ISSUE:
The transmission adapter may cause a misalignment between the flexplate and torque converter causing a pre-load condition between the two components. This concern arises during a transmission flexplate replacement.

ACTION:
Inspect and replace (if necessary) the flexplate reinforcement plate and crankshaft spacer when replacing the flexplate. In addition, replace the engine spacer during this procedure. Refer to the following Service Procedure for details.


SERVICE PROCEDURE

NOTE:
THIS PROCEDURE SHOULD BE USED FOR BROKEN/CRACKED AUTOMATIC TRANSMISSION FLEXPLATES. THIS PROCEDURE IS PARTICULARLY IMPORTANT FOR VEHICLES WHICH HAVE SHOWN REPEAT FAILURES AND/OR LOW MILEAGE FAILURES.

1. Inspect the flywheel reinforcement plate for damage. The plate should be flat and free of any galling. Replace Flywheel Reinforcement Plate (F4TZ-6A366-A) if damaged.

2. Inspect the crankcase spacer for damage. The spacer should be flat and free of any galling. Replace Crankcase Spacer (F81Z-6A366-AA) if damaged.

3. Replace the Engine Spacer (F4TZ-6A369-A).

4. Install the crankshaft spacer and flexplate reinforcement plate (less flexplate) with the flexplate attachment bolts. Tighten to specification. The crankshaft spacer and reinforcement plate should be firmly secured and bolts seated. If the bolts are not seated and/or the parts are still loose, remove the bolts, spacer, and reinforcement plate and bottom tap the crankshaft holes.

5. Reinstall the crankshaft spacer, flexplate, reinforcement plate, and reinstall the flexplate attachment bolts.

 

[justruck]

This May sound crazy, but check the dow pins that go through the spacer to the tranny and make sure they are not worn.

I had a motor replaced, it had the short dow pins about 3/4" long. auto need the dow pins that are 2 and 1/2 long. They align the trans with motor, if not in alighn flex plate will brake.

Just a place to look