Ford 7.3L Power Stroke (1999-2003) :: Loud Gear Meshing Like Grinding Noise - Delayed Hard Shift 2 - 3


Jun 10, 2016

I have an early 99 F250 4x4 7.3L..... 4R100....

Brief history, a while back on way home from work I let off of the accelerator and had a loud gear meshing like grinding noise, got back on the accelerator and went away, let off and back, so I quickly stopped and pulled over, went through the gears and reverse, everything seemed ok,??? went on my way, got home parked the truck and went about my evening. came out next day to leave and truck wouldn't move in reverse, forward but not reverse. long story short I was told that the snap ring internally probably came out, I have heard of this being a big issue with these, so I set up for it to be rebuilt, got it back and installed and still same issue, what the crap so I ended up having to pull it back out and amongst my own trouble shooting I found the simple issue and was the nylon riders on the 4hi/4low shifter fork were completely gone and allowing the planetary group to free float in and out of 4x4 neutral!!! NOW on to the issue at hand. so far only thing has been done is rebuilt and those fork riders replaced.

now I can move but 2-3 upshift under a load(more noticeable) has a delay going from 2nd to 3rd and under a load it hits hard. I talked to the guy that rebuilt it and he said that the rebuild kits don't always the right springs for the valve body and causes shift issues, so he talked me into the shift corrector kit which I researched and did see what he was saying, so had that done and still no better, still does it, however, it does shift into the gear softer but didn't fix the delay or the hitting hard when it did finally go into 3rd.

After being forced to drive it that way I have since determined that what it happening is it is coming out of 2nd with a second and half pause and then shifting into 3rd, the hard shift comes in to play because during the delay the torque convertor is locking up making it a direct drive like popping the clutch on a standard!!!

I just swapped out the sol pack and I heard from a youtube video that the bolt next to the 2-3 upshift valve on the valve body could be to tight and making a sticky valve, so I re-torqued all the bolts and nuts put all back together and test drive proved to be worse, I now have same issue in all upshifts. all hit hard now, I am at a loss and don't know where to go from here, I can only imaging the sol pack is causing this but I have yet put my org one back in to see... oh and I found two bolts on the accumulator stripped and found one non torqued bolt on the main valve body!!

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I noticed my '99 started getting difficult to get in gear & shift, within a coupe of days the peddle was barely off the floor before it would engage. A day later it started 'creeping' if started while in gear. Replaced the master/slave cylinders with no change.

Is a clutch replacement the next step? Just thought I would ask before throwing money at it, since the only other times I've had clutch issues there was slipping or it just plain exploded.

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Well, I think my clutch is falling apart. I am hearing an intermittent nasty noise coming from somewhere in the bell housing/oil pan area. It comes and goes, but seems to be more frequent lately. It sounds like a dryer that somebody threw a pair of sneakers and some rocks in; with a metallic clunking noise of something being "churned" around. As I said, sounds almost exactly like the dryer thing.

The clutch does not seem to be slipping, but I do occasionally have difficulty getting it into gear at a stop. I'm guessing that the clutch disc has thrown a hub spring, and its rattling around in the bell housing. Assuming I need a clutch; which I think I do, I need selecting one. I have no history on the clutch or flywheel, so I will assume that I need a new flywheel to match whatever clutch I get.

I can't get a stock replacement, due to the injectors/chip/etc.... I would estimate I am making about 350hp/700ft-lbs. I don't tow currently, but I may pull a car trailer in the future. I DO haul heavy loads in the bed (4,000lbs) on a regular basis. I also drive/shift aggressively, as well as shifting quickly. While I spend a decent amount of time on the highway, I also do a lot of stop and go stuck in traffic driving; so smooth engagement is important. So, no ceramic/ceramic in/out type clutches.

I do NOT want a South Bend. I don't want a super soft pedal. Also, the whole pedal-sticking-to-the-floor thing they mention is unacceptable. Personally, I think they should be ashamed of themselves for putting out a product with such an obvious unsafe design/engineering flaw, and then try to explain it away as "normal". Nope. They need to go back to the drawing board and fix that. As I said, it constitutes a serious safety hazard.

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The drives side front hub, rear hubs' bearings(races and seals) have been replaced. I have the passenger side front hub to do as well, just haven't gotten to it yet and it doesn't seem bad. we are all stumped on what it is. It seems to relate to the rotating assembly though as it seems to change with speed. it almost seems like tire rub, but there is no scaring or marks of any sort anywhere for it.

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Audio : [URL] ....

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