I am interested in how many manual trannys there are on this web. Also would be helpful to know about known problems with DMF, clutch, throughout bearing, hard and/or squeaky pedal. Any tranny problems.

I haven't had major problems, just a squeeky pedal and occasional hard pedal.

I've had T/O bearing replaced at about 6000 miles. Flywheel at 7000 and I'm rattling again. I also have a squeaky pedal and hard pedal sometimes. The hard pedal is worst when I am running the quad on the 135 setting. I will soon be rid of the DMFhttp://www.dieselplace.com/forum/smileys/Clap.gif

Since I started this gripe I guess I should share my issue:


bought it used with 30K+ miles. shortly after rattled DMF and hard pedal. Later a squeaky pedal.


Dealer replaced the DMF and the slave cyl. Then added a tranny cooler.


Still get hard pedal and slippage. Starting to rattle again when pedal depressed. Still slips a lot (smoked out the dyno day http://www.dieselplace.com/forum/smileys/HiHi.gif). Dealer has a replacement pedal kit on order but no intel of a new flywheel.http://www.dieselplace.com/forum/smileys/Confused.gif

Squeaky pedal and occasionally hard . . . also let a bunch of the smoke out of the original clutch trying a dragster start while pulling 10,600# up a certain hill in Montana . . .thanks to the G80 locker I got no wheelspin.http://www.dieselplace.com/forum/smileys/Embarrased.gif


Got a new slave cylinder, throwout bearing and pressure plate just for complaining about the squeakhttp://www.dieselplace.com/forum/smileys/Confused.gif, but the squeak is gone and so is the hard pedal.http://www.dieselplace.com/forum/smileys/Clap.gif Now my only current complaint is grabby engagement.http://www.dieselplace.com/forum/smileys/Unhappy.gif

I know it is not cheap, but Cpmacs setup should make these 6 gang trucks pretty hard to beat when it comes to towing.

I know it is not cheap, but Cpmacs setup should make these 6 gang trucks pretty hard to beat when it comes to towing.


. . . and racing http://www.dieselplace.com/forum/smileys/HiHi.gif

flywheel replaced at 10,000. Been making noise since 1,000. new flywheel didn't make it past 500 miles. So the truck has 15,000 on it and needs a new flywheel again. Waiting for 5th design. Actually should be reletively soon according to the last time I checked with tech assistance. Also new pedal assembly is supposed to come out to fix the squeakyness. I will be checking in again monday for the new flywheel. (Engine sounds like it is nocking at idle but as soon as you push in the clutch it sounds normal)

Squeaky and hard pedal here also. 3 flywheels through 80,000 miles and going in for #4. love the tranny. hate the clutch, pedal assy., and DMF.

Flywheel replaced @ 16K miles stock truck. Bad again at 42K miles. Always had the squeaky clutch pedal.


I have the hard pedal when travelling on the highway for extended periods of time. I do not believe this is caused by the clutch slipping as I have heard others state. I personally believe it's caused by heat buildup from the throwout sleeve continually riding on the pressure plate fingers for the auto adjustment. I am thinking Craig's setup may fix this as he has an aluminum spacer between the throwout sleeve and the pressure plate fingers (for the single-disc setup). The aluminum spacer ought to dissipate a lot of the heat buildup (hopefully) which will likely cure the hard pedal issue. My fingers are crossed...


I have a single-disc setup from Craig which I am waiting to install once I get the flywheel bolts...


Tim

No problems other than a squeaky clutch pedal when its 90*+.

22k miles, half was with Predator on 40 hp.

Light, frequent loads/towing.

Overall I haven't had any problems with the exception of an occasional hard pedal after a long towing session on the highway. At the moment I have about 55k on an '02.

The factory DMF lasted 72k miles and had it replaced. At 90k miles the second DMF is growling like a bear. Trying to hold out for the new design. Hope it comes out soon!


Love the truck, the ZF, just wish GM would come up with a flywheel that will hang with the rest of the drive train.


MaxRock

MaxRock;


welcome to the diesel place http://www.dieselplace.com/forum/smileys/Clap.gif good to have more members to help share info . . . .hope you enjoy and learn a lot.

I went on a 80 mile run pulling 2 tractors and 2 6 ft bushhogs and could even use the chip because the flywheel would start vibrating and then then clutch would start slipping. And I've had 4 flywheels in 12000. And need a nother one for the last 5000 but waiting for the new one.

My flywheel, input shaft, pilot bearing, release bearing, and the rest of the usual stuff was just replaced last week at 18,000 miles. It had been growling probably since about 6,000 miles. The flywheel had completely separated and rotated over the bolts. The technician told me that it took him much longer to replace the flywheel due to the rotation of the two halves?


I had a pretty good technician. He knew about the PI that says not to replace the flywheel. To get around the issue, he said he thought the noise was a throwout bearing and ordered a new clutch and that the PI was not applicable http://dieselplace.com/forum/smileys/HiHi.gif. This was basically a way for him to get to the flywheel to inspect and replace.


Based on my readings here, I heard there was a new flywheel coming out very soon. One poster had listed it as 4 to 6 weeks (from approximately July 7th). I quizzed the technician and he was told by technical support that it would be another 2 months.


They also replaced my squeaky clutch pedal. So far, no squeaks. But then I've only had the truck back 1 day.http://dieselplace.com/forum/smileys/Clap.gif


Greg

Hey deadeye,


I know your gonna flame me for this but I just had to do it.


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I LOVE MY ALLISON!!!! http://www.dieselplace.com/forum/smileys/HiHi.gif


LOL......talk to ya later buddy

P.S. Thanks for the beers last night!!! next time I'm buying!!!

Hard pedal during long drives or temps over 90F. Squeaky clutch pedal. Other than that no rattles that alarm me too much.


I had a scare last week. Everytime I topped a hill with my trailer doing 75 mph I could smell something bad. I though oh boy clutch probs on the beginning of a week's vacation to Canada. Turns out my new video system has a cooling fan that was cycling blowing hot air on me.

It seems like the power adders are what is really hurting the flywheel. When I had mine replaced I took it to Kansas to pick up a 30' GN trailer with a 16' steel livestock and a 12' steel truck bed on top. I ran the Quad on 70 while loaded. As I came back the flywheel would growl on the hills with the cruise set. By the end of the trip the flywheel was growling a lot easier than when I started. I guess stock power may be the way to go with a stock clutch. It sure was fun out pulling the Dodges on the hills though.http://www.dieselplace.com/forum/smileys/HiHi.gif

Hey deadeye,


I know your gonna flame me for this but I just had to do it.


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I LOVE MY ALLISON!!!! http://www.dieselplace.com/forum/smileys/HiHi.gif


LOL......talk to ya later buddy





wait until you have to pay Clint to update (fix) your Allison and you will wish you had a ZF6 http://www.dieselplace.com/forum/smileys/HiHi.gifhttp://www.dieselplace.com/forum/smileys/HiHi.gifhttp://www.dieselplace.com/forum/smileys/HiHi.gif


BTW, next time we meet up you best bring your banker . . . to pay for the beer http://www.dieselplace.com/forum/smileys/Clap.gif

after 22k on the orignal clutch and flywheel, while pulling a loaded live stock trailer Sat. going up 8-9% grade the flywheel would growl if I ripped on the throttle hard. The unit has been runned about 15k with the PPE cranked up. Had no problems with the ZF. Is there a cooler that can be put on these? I also suffer from the stiff pedal after long runs without any clutch engagment. After the first application the pedal goes right back to normal. The pedal will squeak once in the blue moon also.

Did some hard draggin, dyno pulls and she still don't slip (knock on wood!!!) but your right when she goes it's gonna kill the pocket book!!! but at least I can have some fun with it......sounds like you all have problems with the DMF from the get go!!!

Anybody know where CPMac is with his replacement. He seems to have dissappeared. I haven't seem him post in this new forum.

I had either2 or 3 flywheels go bad before I put a chip on mine. Mines been put on a dyno and it pulled great. After a period of time the flywheel will eventually toast the clutch from chattering. I talked to a person at Luk to see if they had a solid flywheel and they said they didn't. And they wasn't planning on making one. And he also told me that they made the flywheel for the Duramax. So if he knows what he's talking about, the next flywheel will still be 2 piece flywheel.http://www.dieselplace.com/forum/smileys/Cry.gif

I'm sure the GM flywheel will be 2 piece. I think CPmac may have the market secured for 6 speeds. I don't think there are enough out there for larger companies to spend the time and money to develop replacements.


As far as CPmac goes, he has been VERY busy and hard to catch. I talked to him today and he had just left to do several installs in Ohio.. one being minehttp://www.dieselplace.com/forum/smileys/Clap.gif If I can figure it out I will post pics when I get them. Should be Wed or Thurs.

The factory DMF lasted about 65k miles. I'm now at 90k and the second one is growling. The truck is bone stock except for some minor upgrades...nothing to the engine. So tuners may cause an earlier failuer, but in stock trim the DMF will crap out also.


Thanks for the welcome. I've been a member at the other site for a couple of years and have slowly started grazing this site. A heck of a lot more traffic over here!


MaxRock

mine went with no add ons just stock power. at 500 miles and second one at 10,500 miles. It is not the way I drive it because if that was the case the 02 duramax with a mason dump body on it would be in the same situation. It has 50,000 on its original flywheel.
Strange isn't it.

after 22k on the orignal clutch and flywheel, while pulling a loaded live stock trailer Sat. going up 8-9% grade the flywheel would growl if I ripped on the throttle hard. The unit has been runned about 15k with the PPE cranked up. Had no problems with the ZF. Is there a cooler that can be put on these? I also suffer from the stiff pedal after long runs without any clutch engagment. After the first application the pedal goes right back to normal. The pedal will squeak once in the blue moon also. Yes there is a cooler you can put on the ZF. My dealer put mine on under warrenty

after 22k on the orignal clutch and flywheel, while pulling a loaded live stock trailer Sat. going up 8-9% grade the flywheel would growl if I ripped on the throttle hard. The unit has been runned about 15k with the PPE cranked up. Had no problems with the ZF. Is there a cooler that can be put on these? I also suffer from the stiff pedal after long runs without any clutch engagment. After the first application the pedal goes right back to normal. The pedal will squeak once in the blue moon also.


Yes there is a cooler you can put on the ZF. My dealer put mine on under warrenty


ditto.

after 22k on the orignal clutch and flywheel, while pulling a loaded live stock trailer Sat. going up 8-9% grade the flywheel would growl if I ripped on the throttle hard. The unit has been runned about 15k with the PPE cranked up. Had no problems with the ZF. Is there a cooler that can be put on these? I also suffer from the stiff pedal after long runs without any clutch engagment. After the first application the pedal goes right back to normal. The pedal will squeak once in the blue moon also.


Yes there is a cooler you can put on the ZF. My dealer put mine on under warrenty


ditto.


Where can I get more info on Trans cooler?


Dealer's here (several) never saw a ZF until mine.

I will look at mine at lunch and get back with you.








My cooler is a cool-man cooler. I will try to find the phone # tonight.Edited by: gearhead

I cannot believe there are only 29 ZF6 owners out of the 7000+ members on this site. Come on. . . VOTE !!!!http://www.dieselplace.com/forum/smileys/Ermm.gif

there, 30.... http://www.dieselplace.com/forum/smileys/Big Smile.gifhttp://www.dieselplace.com/forum/smileys/HiHi.gif

hey tired old man call Precision Power Injection, Inc. @ 1-800-432-7269 and ask them about there coolman transmission coolers thats were mine came from

Have about 17,000 miles on my 2002 DM-ZF6 pulling 7500 lb travel trailer. I bought it new and no problems yet, but you guys are starting to scare me!!


A mechanic told me that the ZF6 transmission was made by Mercedes. . . any truth to that??

The trans is made by a German company, not Mercedes. ZF specializes in drive line products. MOre information can be found at ZF Industries (http://www.zf-group.com/am/pc/lt/ampclt03.phtml).


When I changed my trans fluid, I think it was 5 or 6 quarts, but I could be wrong.

Have about 17,000 miles on my 2002 DM-ZF6 pulling 7500 lb travel trailer. I bought it new and no problems yet, but you guys are starting to scare me!!


A mechanic told me that the ZF6 transmission was made by Mercedes. . . any truth to that??





If you are luck, and everything is stock, you might not have any worrys. The 3rd p/n DMF just came out. You are warrantied on that part for 100K miles. Clutch may be a different problem unless the DMF trashes it. you haulin' flat or in the mountains? don't think the weight your draggin' is very much. Just pay close attn to the noises in the tunnel.

Does anyone other than CPMac offer a heavy duty clutch for these things? I can't reach him, I leave messages but he doesn't call back.

Does anyone other than CPMac offer a heavy duty clutch for these things? I can't reach him, I leave messages but he doesn't call back.


I have the same problem. I don't think anyone else does. . . .

My 03 d/max just turned over 10,000 miles and lately my truck is making a very bad rattling soud on DECELERATION. Is weird because none of you mention it on decel, only under power. Do you suppose my problem is differant? It kind of acts like a clutch chatter, but not under load. I don't have a squeeky or hard pedal, just the rattle. Any ideas?


Jim

Found one other source for heavy duty Duramax clutches:

http://www.drivetrain.com/heavydutyclutch.html

Also, the people at http://www.clutchplace.com/ say they can make me one, but I'm still waiting for a quote.

My 03 d/max just turned over 10,000 miles and lately my truck is making a very bad rattling soud on DECELERATION. Is weird because none of you mention it on decel, only under power. Do you suppose my problem is differant? It kind of acts like a clutch chatter, but not under load. I don't have a squeeky or hard pedal, just the rattle. Any ideas?


Jim








mine rattles now when I decelerate with the gear too high. . . it probably is the flywheel . . sounds very similar to the noise at engagement and disengagement of the clutch.

Found one other source for heavy duty Duramax clutches:

http://www.drivetrain.com/heavydutyclutch.html

Also, the people at http://www.clutchplace.com/ say they can make me one, but I'm still waiting for a quote.


I don't suppose either of these places make a SMF (flywheel). No point in installing a HD clutch or pressure plate if the flywheel is OEM DMF. It will just trash the flywheel faster.

I guess I'm holding out some hope that this latest DMF will hold up better. Kinda hate to go to a 1 piece, really don't want more NVH.

36,500 miles and no problems but the occasional stiff pedal and squeek. I consistantly pull close to the max gross rating of the truck in the mountains and don't have any of the symptoms of the bad flywheel. I don't abuse my truck but I work it EXTREMELY hard in the hills here in Colorado. I am somewhat sceptical of some of the people saying they have replaced theirs every 5000 miles or 5 times in 2 years. I'm not saying their lyars, if it's true I'm sorry to hear your bad run of luck, but as we know a lot of F*#D and Dodge guys like to throw in bogus stuff here.

I know it's hard to believe, but a lot of these flywheels have been replaced very often. I had my truck in the shop 4 times in the first 8000 miles. One T/O bearing, one flywheel, one water pump, one water pump seal. Believe me I love my truck and bleed chevy, but I did have a rough start. She's good since then though, of course the SMF and DD helps http://www.dieselplace.com/forum/smileys/HiHi.gif

I just notice that 728 view of this poll and only 46 votes???? http://www.dieselplace.com/forum/smileys/Confused.gif

Gray Max;


I finally caught up with Craig this morn and he indicated that he will ship a dual disk kit this week http://www.dieselplace.com/forum/smileys/Clap.gifhttp://www.dieselplace.com/forum/smileys/Clap.gifhttp://www.dieselplace.com/forum/smileys/Clap.gifhttp://www.dieselplace.com/forum/smileys/Clap.gifhttp://www.dieselplace.com/forum/smileys/Clap.gif


I am really excited. I was also suprised to catch him on the phone but I have been callin him three times a day, every day for three weeks an finaly got lucky!!! http://www.dieselplace.com/forum/smileys/Cool.gif


I will take pics of the parts and the installation once it gets started.


Wish me luck.

I have 86k on my truck now and no problems with the clutch (yet). If I don't depress the clutch pedal when shutting down it makes a nasty noise, but other than that it does NOT make any noises. I do get the occasional hard pedal on long trips. The clutch pedal was replaced at 30k miles for squeaking. It still does it. I may try to get another one since it appears they have a new pedal.

1BADDMAX, I recommend the new pedal. I haven't had one squeak yet.

I cannot believe there are only 29 ZF6 owners out of the 7000+ members on this site. Come on. . . VOTE !!!!http://www.dieselplace.com/forum/smileys/Ermm.gif


once again . . . . vote on your tranny/clutch/flywheel status. http://www.dieselplace.com/forum/smileys/smiley32.gif

Ttt

In the for what ever it is worth dept. I believe that the hard pedal is heat related.
Mine run in excess of 250 degrees on flat ground on hot days, pedal pressure was very hard @ those temps. I lowered the temp aprox 40 Degrees by installing STP ( old salt flat trick )

Since I have install Craig's Macs-Performance Dual Disc Puller (Flywheel/clutch) Kit I have had no hard pedal issues, no slippage, and the only pedal noise is very minor when ambient cab temp is high and I stand on the pedal for a while. The pedal takes more strength to operate than the OEM so I hope I never get stuck in another 1 hour traffic jam !!! The only issue I now have is squealing when engaging the clutch as the plate has a lot of metal in the pads. I just go fast and don't pay any attention !!!

Just FYI, I will be trying a new set of Disc from Craig, hopefully sometime this month. I am hoping to get a little smoother engaugement. I will keep my findings posted.

Just FYI, I will be trying a new set of Disc from Craig, hopefully sometime this month. I am hoping to get a little smoother engaugement. I will keep my findings posted.
Thanks. I am finding the engagement to be a bit frustrating. . . seems the point of engagement changes all the time, ambient temp, engine temp, uphill, downhill, flat, Edge level . . . . I been drivin manual for years. This is getting a little hard for this old guy . . .

Craig came over last weekend because the clutch "burned out" slippin. Once it was back together it was much better and different than the original install. The pedal was much softer, engaged easier, and was quieter! If I concentrate when starting from a full stop it works very similar to stock. If I don't match the rpms properly with the engagement you can sure tell it ain't stock):h

bump . . . . . no one else with problems (or not) since Sept ?????

Got the latest part # flywheel installed 12-15-04. So far so good as far as the flywheel goes. Still have a slipping clutch at 90 horsepower and above. Pedal starts getting stiffer at 65 horsepower.

Got the latest part # flywheel installed 12-15-04. So far so good as far as the flywheel goes. Still have a slipping clutch at 90 horsepower and above. Pedal starts getting stiffer at 65 horsepower.

If you don't back down on the Edge both the clutch and the DMF will trash again . . . .I know from experience

I ran it stock for a long time after getting it back. Now it's just on the Predator 40HP setting. Kinda sucks not being able to run WFO. But it'll all be good again when I get something from CPMac. ;)

The clutch from cpmac is the way to go boys. 12000 on mine and doin grate. It is kinda jumpy sometimes but that comes with the fun of performance. we are puttin new disks is GrayMax's truck soon to fix the jumpy thing. These disks are not for pullin though. "winter disks" you could say....

anymore folks with clutch/DMF problems?

Found one other source for heavy duty Duramax clutches:

http://www.drivetrain.com/heavydutyclutch.html

Also, the people at http://www.clutchplace.com/ say they can make me one, but I'm still waiting for a quote.

have you found anyone besides CPMac making a replacement SMF flywheel?

Hey Deadeye...see ya Sat!
Yes, I am on DMF #2 already and headed for #3... plus the factory on so really #4. The first one was replaced by previous owener in AZ at like 4K and I bought the truck from him at 17K. First time took it to Purifoy at 28K and they didn't have a clue ended up replacing the Pilot Bearing and that was it...gave it back me making the same damm noise said they didn't know what else to do....WTF kind of service is that??? Then I took it to my ol'buddies at Weld Co Gar at 35K.... I used to work there way back...anyway, they knew what it was immediately. They replaced the DMF, T/O, and Pilot Bearing and threw in a new clutch...who knew pulling 20+k eats'em up fast HA HA!! I was hauling cars for a bit to make ends meet had a 50ft 3 car, big load for 2500 still pulls the hell outta of it though and smoked my buddies Ford up to Aspen!! Now at 51K and it started making the noise about 3K ago, so back it goes for #4. Or if my money tree starts producing a CPMac's single or the Rhino for a clutch!! Isn't ATS working on a Flywheel?

D'DOUT;
hOPE TO MEET UP WITH YOU ON SAT. i AM GOIN TO BANDEMERE FIRST AND THEN DYNO ABOUT 1 OR SO. GOT TO HOOK UP WITH CHAD AND GET SOME TECH2 ANALYSIS. ATS TOLD ME THEY HAD SOUTHBEND WORKING ON IT BUT THAT WAS LAST SUMMER AND I HAVE HEARD NOTHING ELSE. YOU MIGHT WANT TO EMAIL MCCLOUD OR MCLEOUD (SP?). THEY BOTH DO CLUTCHES AND MECLEOUD, I KNOW DOES RACING AND PULLIN KITS. JUST DON'T KNOW IF THEY DO THEM FOR A DMAX. i HOPE SOMEONE IS BECAUSE I CANT GET HOLD OF CRAIG FOR REPLACEMENT DISCS. :mad:

Of course I have a growling dmf that I will be replacing with CPmacs single disc setup(so my wife can still drive it?)I've also had the squeeky pedal too.I've been able to spray lube on and make it go away for about a month at a time.The noise comes from the bushing that connects the pedal assem. to the master cylinder push rod.I broke this piece a couple of days ago when I was spraying lube on it I pulled up on the pedal too much and it snapped.I ordered a new bushing(I haven't got it yet)but it seems to be different than the old one,maybe the cure for the squeeky pedal?I let ya guys know.

Damn... this makes me wonder how I'm still on the original DMF @ 103k!!!
No strange noises etc. Is there anyone on here that has over 100k on their original DMF?

:( Just had number three DMF installed, 19 K, no performance upgrades. Last one lasted 2K and pulled nothing. I baby this truck and if it keeps this up out with the Chevy and in with a Dodge. Not to mention the eight new injectors at 18K.

Squeeky , Hard Pedal , 2 Flywheels In 75,000 Miles

D'DOUT;
hOPE TO MEET UP WITH YOU ON SAT. i AM GOIN TO BANDEMERE FIRST AND THEN DYNO ABOUT 1 OR SO. GOT TO HOOK UP WITH CHAD AND GET SOME TECH2 ANALYSIS
Definately will, I was torn between the Rollers and the Strip...hmmmm where to burn up the clutch first?? I think I will show up at Bmere first, I really want to see Chad's truck run the QM !! Plus I need him to check my injector rates, last few weeks something doesn't seem right with the way its' running, guess we'll see. Anyhow, look forward to meeting a fellow handshaker!!

:cool2:

What kind of noises does the flywheel make when it is going bad. Please forgive me, I'm new to this.:iamlost:

28k miles, pry 20k miles running a 40 hp tune........

I like to shift too............

No trouble.