Zf5 insane roll over noise

Alight so I’ve been rummaging through threads trying to find something that applies to this situation

So, I’ve got an 88 f350 4x4 just did a rear main smf conversion clutch pilot bearing pressure plate

Worked like a top for about a week no oil leaks just normal roll over noise but on the way home yesterday another thread said it best “sounds like trans is full of rocks” its ok in first gear and second and then when going to neutral after second, it's like BAM. and I noticed that the rear main is slinging a sh** ton of oil the night before it was bone dry not even sweating

I got extremely concerned and popped the pto cover off and inspected all that I can see, and nothing was bad no metal or gear damage

I feel like the rear main and this roll over noise are correlated events

The big thread about roll over noise was solved by driveline angles. But that was some crazy old truck swap, so I feel like my driveline angle didn’t magically change

What’s going on here?

If the rear main is leaking that bad, the clutch is slipping.


Rock

Pull the trans and find out.

Leaking rear main will definitely lead to clutch slip which can make a ton of racket. Could also have a snapped shaft or damaged synco in the trans. Either way, it needs to come out.

The clutch slipping was my first thought and what I’m most hopeful for, I was already planning to pull it
Fingers crossed

It is making the noise with the clutch in and making the shift?

"Rollover" noise is usually at idle with clutch out, trans in neutral.

Black dawg said:

It is making the noise with the clutch in and making the shift?

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When it’s making the noise it severely dampens when clutch is in but is still faintly there… just remembered that

Transmission perfectly fine just took it out everything looks flawless no input shaft play all the gears look brand new

But the brand new flywheel looks like this heat marks from presumable slipping pressure plate looks the same is this going to be an issue running this?

Do y’all see anything wrong with the way I installed the rear main either?

Looks like there's a small drop at the bottom of the rear main seal. Is that just residual?
That flywheel will need turned or replaced, that's pretty significant wear.
How's the release fork on the trans look? I've seen the tangs be bent, and cause it to not release fully. I've also seen the throw out bearing not seated in the fork correctly, and it kept the clutch partially disengaged the whole time.

Why is there a long shadow on the bottom part of the rear main seal? Is it in all the way? Those large seals like that can be difficult to install, the factory uses a special tool to install them. They are so big they are weak, its easy for them to be wavy if they are not driven in evenly all the way around. Any waviness will cause them to leak.

Did they give you a driver with the seal? If not, maybe you can get a new one and check a local machine shop and see if they have one to drive it in straight.

Theres rubber in the crank sleeve?
When I put the clutch on the input shaft I can tilt it like 10 degrees is that normal?
The tangs on the fork apeared not to be bent

Does that fork look ok to y’all I’ll it’s a bad picture I can only take .5x
I found some shims on the input shaft are these supposed to be here? If not maybe that’s why the clutch was getting wierd?

is this an issue or is this normal
It’s precision clutch from rock auto a part of the “solid flywheel conversion kit”

Austin86250 said:

Theres rubber in the crank sleeve?

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Are you sure that it's rubber and not RTV? I haven't seen that style of sleeve before so it all looks strange to me. That's just an observation so don't think it means anything.

Austin86250 said:

Does that fork look ok to y’all I’ll it’s a bad picture I can only take .

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From what little I can see, it looks ok to me. I've heard of forks that have cracks in them so check it all over closely for cracks.

Austin86250 said:

I found some shims on the input shaft are these supposed to be here?

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I also haven't seen those before and I have no idea what they would supposedly be doing.

Austin86250 said:

is this an issue or is this normal

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Again, it's hard to tell from the video, but a clutch isn't a tight tolerance fit. A little bit of movement like that is probably normal. As long as the very center piece of the clutch that has the splines isn't loose from the rest (I couldn't tell), then it's probably fine too.

IDIBRONCO said:

Are you sure that it's rubber and not RTV? I haven't seen that style of sleeve before so it all looks strange to me. That's just an observation so don't think it means anything.

From what little I can see, it looks ok to me. I've heard of forks that have cracks in them so check it all over closely for cracks.

I also haven't seen those before and I have no idea what they would supposedly be doing.

Again, it's hard to tell from the video, but a clutch isn't a tight tolerance fit. A little bit of movement like that is probably normal. As long as the very center piece of the clutch that has the splines isn't loose from the rest (I couldn't tell), then it's probably fine too.

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no I’m not 100% on if it’s rtv or
Not but it’s the same exact color as the seal and the rtv I used was black and so was the rtv used prior