Smooth Clutch Engagement Gone

[jmatero]

Are there any clutch experts who can help? I have 3000 miles... My flywheel and clutch assemblies have been replaced twice already because my clutch engagement is on/off... Meaning, I'm unable to get the clutch to engage smoothly (from stops in 1st) without the car jerking/bucking. My coworker and I purchased identical cars within a week of each other and I drove his again - beautiful progressive engagement. I drove another new GT at the dealer - beautiful progressive engagement. Get back into mine - jerk-buck. It feels like there is literally a half inch of pedal travel between ENGAGED and DISENGAGED. During the last repair they replaced everything between the crank shaft and the driveshaft. In my mind, this leaves 2 possibilities:

1: The master cylinder is the culprit
2: Something is going wrong during reassembly (grease on disc, etc)

I've been extremely patient as my car has been in the shop for this and the shifting issues 4 times now. Can anyone here give me some guidance as to how I should move forward? The car is not functioning like the dozen I test drove before making the purchase, my coworker's car, or even MY car when I took delivery.

 

[RSKtakR]

Are there any clutch experts who can help? I have 3000 miles... My flywheel and clutch assemblies have been replaced twice already because my clutch engagement is on/off... Meaning, I'm unable to get the clutch to engage smoothly (from stops in 1st) without the car jerking/bucking. My coworker and I purchased identical cars within a week of each other and I drove his again - beautiful progressive engagement. I drove another new GT at the dealer - beautiful progressive engagement. Get back into mine - jerk-buck. It feels like there is literally a half inch of pedal travel between ENGAGED and DISENGAGED. During the last repair they replaced everything between the crank shaft and the driveshaft. In my mind, this leaves 2 possibilities:

1: The master cylinder is the culprit
2: Something is going wrong during reassembly (grease on disc, etc)

I've been extremely patient as my car has been in the shop for this and the shifting issues 4 times now. Can anyone here give me some guidance as to how I should move forward? The car is not functioning like the dozen I test drove before making the purchase, my coworker's car, or even MY car when I took delivery.

I made Ford replace my master cylinder (brake and clutch are one assembly) when they replaced my entire clutch assembly so the entire system is new. I would take it back and have the service manager drive the car.

 

[jmatero]

When he drove it the first time with the engineer, he stalled it... he said he "just wasn't used to it"... and suggested I wasn't driving it correctly. I've been driving stick exclusively for 27 years... I've driven the worst (1981 Plymouth Reliant) and the best (2004 & 2008 Miatas). I've also NEVER needed a clutch replaced and I'm on my 3rd already in this car within the first 3000 miles.

 

[RSKtakR]

take it to a different ford dealership.

 

[Mike@PowerHouse]

Sounds as though the mastercylinder may be the culprit, or the unit wasnt properly bled...

 

[jmatero]

It's the only part left other than the pedal assembly, right? I told them to replace it so I wouldn't have to come back and they didn't. Are you able to explain how the master cylinder could cause this? Inconsistent hydraulic pressure? There are no leaks and I'm on my 3rd clutch assembly at this point so it's hard to believe they aren't bleeding it right so many times, no. Any advice would be greatly appreciated!

 

[blue streak]

take it to another ford dealer if possible, and tell them whats been going on and whats been done. and then tell them from your experiences, you think its the master cylinder. that is the only thing left..

 

[tigerhonaker]

All I can add is this.
Good-Luck !!!
I Hate clutch issues.

Oh and I will add this comment and maybe it might be of some Help.
I worked for Car Dealers for 15 Yrs. and I can tell you take it to
another Dealer.
Oh and Call Ford Customer Support/Relations and get a CASE going (Officially).

tigerhonaker

 

[Whocares05050]

Any update OP? My clutch did the same thing and out of no where the same day the car wouldnt shift into any gears and the clutch was not smooth, just on and off and felt like a sponge. cars at ford now awaiting the tranny to be rip apart to find the cause.

 

[jmatero]

It's on the 3rd clutch and 2nd transmission and they can't figure it out. Ford asked me to drop it off at a different dealer this morning... Let's see if they can fix it!!! I have 3000 miles

 

[Whocares05050]

damn dude. lemon law that bitch

 

[jmatero]

Great... They say it's normal. Beautiful. Beautiful. Just beautiful. I give up.

 

[Stangmancs]

I have intermittent sponginess also. Sometimes I have to force mine into first. The weirdest thing is that when I'm stopped at a light I can ease the shifter near first gear and the car will move forward with the clutch totally out.

 

[jmatero]

I'd bring your car in. If the pressure plate bolts backed out, the clutch won't fully disengage despite having the pedal down all the way. Known issue and Ford has redesigned the bolts and updated the torque specs.

 

[JEWC_Motorsports]

http://www.lemonlawamerica.com/

force them into getting you a new car.

 

[Jonbones]

I'd bring your car in. If the pressure plate bolts backed out, the clutch won't fully disengage despite having the pedal down all the way. Known issue and Ford has redesigned the bolts and updated the torque specs.

this. They did all the TSB's to my car before I took delivery. I insisted upon it, and told them I would not be purchasing the car if they were not complete. They took a car off the lot, ran it through the service dept, and a week later, I was on the road and havent had 1 issue since. ( knock on wood )

 

[Whocares05050]

I'd bring your car in. If the pressure plate bolts backed out, the clutch won't fully disengage despite having the pedal down all the way. Known issue and Ford has redesigned the bolts and updated the torque specs.

Yup. just got mine back from ford. every single bolt backed it self out/ was loose. car drives better than new now.

 

[Jonbones]

good to hear....no get out there and enjoy shifting that badboy, damnit!!!

how about the OP?