I need some help here. I am having some major problems with the clutch/transmission.
I've had it with the stupid POS!!!!!
The throw out bearing is not working properly still. It is not releaseing so that it doesn't touch the pressure plate, should it? Anyway the bearing is vibrateing/moving and it makes a racket. Here is what I have done so far.

New pilot bearing
New clutch disk & pressure plate
New throw out bearing
New slave clynder
New input shaft bearing

Had the transmission gone through by a mechanic and he said the only problem which was not really bad but the input shaft bearing had some slop in it.

1993 F150
4.9L
4x4
4 Sp. Borg Warner
Borg Warner transfer case

 

The throwout bearing will ride on the pressure plate all the time in your model of truck. If its making noise you probably got a bad bearing, worn bearing retainer, or it was installed wrong. Exactly what kind of noise are you getting and when does it happen?

 

it is making a squeel and friction grinding sound. I put the third new clutch assembly in the darn thing today. The noise it makes will change at certain areas of the pedal travel. The bearing was put in properly and the clutch fork (release fork) is brand new also. The bearing can only go one way otherwise it would go through the pressure plate and the fork would hit the pressure plate.
I had the truck towed home on April 2nd but did not start working on it until April 11th. So far I have taken the tranny and every thing out 6 times and tried three clutch kits. I tried two Power Torque and the one that's in there as of today is a Borg Warner kit. I like to think I know a bit about trucks and I am mechanicly inclined, but I just don't get this. I did my 87 in 1 hour and 10 minutes (me and another guy) over a drive over pit and had no problems with it for 3 years, and it was still going strong when I traded it in. This thing has me baffeled beyond all else.
I am self-employed and I need my truck back, working out of a car limits the work I can do. I am hopeless.

Hopeless Steve

 

Have you looked at the transmission bearing retainer?(the piece the throwout bearing rides on) Is it smooth and free of burrs and uneven spots? Does the throwout bearing fit good or is it real loose on there? Does the "hub" of your throwout bearing have ears or tabs on it to keef it fron spinning in the clutch fork. Does the noise ever go away?

 

Well the noise does go away sometimes but not very often. Sometimes it's when the pedal is to the floor and other times when it's coming back up, or all the way released. The bearing does fit snug on the fork and it can't spin. The fork is brand new and has maybe 10 or 15 miles of use on it. To me, an untrained eye, the fork doesn't seem to be in the "perfect" position, meaning it always seems a bit high or low of level.
I apprecaite your help Ford302Guy, this has been a nitemare for almost 8 weeks. I worked through snow, rain,wind, sun and everything else, I am tired.