Burning smell after clutch replacement

[Sharky146]

Hey guys.

The Problem: My truck smells like burning transmission fluid when at highway speeds above 50 mph. There are no visible fluid leaks. I can only smell it with the windows down, but it’s a pretty strong smell. I don’t notice it at all below 50 mph.

This smell started right after I just did a complete clutch job on my 2006 Ford ranger FX4 4.0L 5-speed manual. This job included the clutch disk, pressure plate, flywheel, slave cylinder, master cylinder, rear main seal and transmission input shaft seal. I also replaced the tranny fluid with new Mercon V. (The Haynes manual says to use Mercon, but the Autozone only had Mercon V.) I’ve only put about 150 miles on the truck since I finished the clutch job, I’m hesitant to drive it any more until I figure out what’s wrong with it.

It was my first clutch job. It took some time, but wasn’t terribly complicated. Just wondering if I made a bonehead mistake along the way that is now causing the burning smell. Could it be the Mercon V? Any other ideas?

Thanks guys.

 

[Sharky146]

Hey guys.

The Problem: My truck smells like burning transmission fluid when at highway speeds above 50 mph. There are no visible fluid leaks. I can only smell it with the windows down, but it’s a pretty strong smell. I don’t notice it at all below 50 mph.

This smell started right after I just did a complete clutch job on my 2006 Ford ranger FX4 4.0L 5-speed manual. This job included the clutch disk, pressure plate, flywheel, slave cylinder, master cylinder, rear main seal and transmission input shaft seal. I also replaced the tranny fluid with new Mercon V. (The Haynes manual says to use Mercon, but the Autozone only had Mercon V.) I’ve only put about 150 miles on the truck since I finished the clutch job, I’m hesitant to drive it any more until I figure out what’s wrong with it.

It was my first clutch job. It took some time, but wasn’t terribly complicated. Just wondering if I made a bonehead mistake along the way that is now causing the burning smell. Could it be the Mercon V? Any other ideas?

Thanks guys.

I forgot to mention that the transmission shifts very smoothly, clutch pedal engages in the right spot, and there are no unusual noises. Other than the burning smell, it runs great!

 

[600$04Ranger]

I forgot to mention that the transmission shifts very smoothly, clutch pedal engages in the right spot, and there are no unusual noises. Other than the burning smell, it runs great!

I have an 04 with a new clutch that has a weird smell only when backing a small(1000-1500lb. load) trailer up a moderately steep driveway. Sort of a burning gear oil smell. Hard to describe. Mine shifts nicely and doesn't stink in any other situations as far as I can tell. Maybe you could try partially engaging the clutch with the truck on jackstands to see if you can generate the smell and isolate it's source. Not sure if that would work but it's all I could think of. I'm an amateur mechanic who has managed to figure out most tasks/problems/upgrades eventually but not without plenty of frustration and time consuming misdiagnosis. Good luck!

 

[Eddo Rogue]

Maybe just residual fluid burning off of the hot parts? or maybe a small leak at the seal that was replaced. Also Clutches do need a break in. Maybe you spun it and glazed the disc a bit...

 

[RobbieD]

Have you been back underneath and looked for any evidence of a fluid leak? And, is yours the Mazda 5-speed that has the rubber shift rail plugs, and if so, have these been replaced or upgraded to metal freeze plugs?