:::Very Unusual Gearbox Problem (Help!)

[NDL01]

I have a 2001 Ranger 2.5L 5 speed. The truck has 182,000 fairly trouble free miles.

The intention of this post, is to gather information that I will pass on to my mechanic. While I can perform tuneup's and routine maintainance/fluid changes, the below problem is above my paygrade.

I am a professional driver (Class A license holder). I know how to properly shift a manual transmission.

I had 100k on my original clutch; most of that was stop and go driving. At around 100k, I had the clutch, slave, etc., replaced.

At 150k, my problems began...

Making a 3 point turn on a narrow gravel road, the rear of the truck rolled into a small gulley. To get out of the gulley, I lightly popped the clutch. Coming out of the gulley, I heard an unusual sound – not a whine, more (somewhat) like a rattle.

At around 160k, my clutch gave out. Took it to a different shop. Turns out that a few of the bolts on my flywheel were shimmed. The springs on my clutch broke (hence the odd sound when pulling out of the gulley). New clutch/slave put in.

At around 170k, the pressure plate went out. New clutch put in under warentee.

Now at 182k, the clutch went out again. Turns out the springs on the clutch broke (please see attached picture).

The shop I took it to has a stellar reputation. The mechanic was recommended to me by an acquaintance who maintains a fleet of vehicles for the City. The shop is very neat and clean. The technician uses good parts, is fairly priced, and his work is spot on. In other words, I don't think it's the shop.

The flywheel is fine; the driveline looked fine; there's no slop in the crankshaft. The truck drives fine; no unusual vibrations/noises. When the clutch operates, it operates excellently. There's nothing visually wrong with the setup.

No one can figure out why this is happening.

Sorry for the long post. Wanted to include as much detail as I could. I thank everyone for their help! I can't afford a new truck right now, nor can I afford continual issues with my gearbox.

 

[4x4junkie]

Are they using Luk brand clutches? ( I can't recognize the markings I see on the disc) I've seen some other clutch brands fail in strange ways like you describe (breaking springs to the friction material outright disintegrating). Luk is also made in USA (at least last time I checked they were).

 

[baddis]

I have seen this happen before but not on a Ranger. When it happened on a friends 1 ton chebby we replaced the flywheel along with the clutch. If i remember right the trans was not tight to the bellhousing. (doesn't apply in your case) It is possible that the bellhousing bolts weren't tight is all I can think of.

 

[NDL01]

I thank you both, for your helpful replies

To the first poster: you are dead on; the clutch is Ford OE, which is supposedly manufactured by Luk.

After a search, I found others complaining about the same thing with Luk brand clutches.

Off of Luk's own guide to premature clutch failure, they claim that letting the engine lug in too high a gear, can blow the springs. Admittedly, I short shift the engine. Maybe Luk's clutches are more problem prone in this regard.

When I replaced the clutch last time around, it was a Napa brand clutch. I'll pick up the revs, hoping that this doesn't happen again.

Thanks again for y'all's help.

 

[4x4junkie]

I didn't mean to imply Luk was problem-prone, exactly the opposite (Luk is about the best there is in a standard-replacement clutch).

Lugging and short-shifting certainly can cause problems though (not exactly good for the engine or your MPG either). You should probably shift at something around 2500 RPM just in normal routing driving (much higher if you're hard-accelerating)

Anyway, good luck with it.