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Clutch slipping when in boost

Is the South Bend Clutch worth it

  • Yes, if you're going to offraod you need this upgrade

  • No, doesn't truly improve offrad reliability

  • Who knows, nobody has been dumb enough to pay for it


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Tonka13

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22 Bronco Base 7MT Sasquatch 25k Miles

I was driving on the freeway and downshifted to make a pass when the Bronco went into a reduced power mode. I pulled over and turned the truck off then back on and the issue went away. About a week later I was going up a hill and when the Bronco started using boost the same thing happened. This time I noticed that the engine speed increased at a faster rate then the truck accelerated before it went into the reduced power mode. I connected to get the code read and confirmed the code specified clutch slippage. I can recreate the issue anytime now just by being in gear at pretty much any cruising speed and then trying to accelerate in the same gear. When boost comes on the clutch will start to slip. The odd thing is that it only happens in this specific scenario or when going uphill. Otherwise the Bronco can be driven normally with no issue. As long as there is no agressive acceleration, the clutch engages and shifts normally.

I've driven MT my whole life, I have never experienced a clutch go out like this. In my experience, a worn clutch would have noticeable pedal degredation and difficulty engaging gears at low speeds such as starting from a stop. I'm worried this may not be a worn clutch, but a more complex issue. I'm planning to have the clutch removed next week to inspect and potentially replace but wanted to see if anyone else has had this experience.

I have taken it offraod in the past and when in the sand or snow, where you have to ride the clutch a bit to keep from stalling, I have noticed a burning smell afterwards. Nothing that in my experience would indicate a complete failure, and only noticeable when standing outside the vehicle.

I remember Ford initially was not planning to offer the MT with the Sasquatch pkg, but eventually did. I had to wait an extra year on my order because of this. I'm wondering if the OEM clutch is just not up for the stress put on it when offroading. I've been looking into a replacement, but options appear to be limited. The only one I can find is the offerings from Southbend Clutch. Based on my limited research, I was looking at their endurance clutch for a more reliable offroading application. They also offer a daily and drag version, though I can't imagine why someone would be drag racing a Bronco, if that's truly what that version is for. Has anyone had experience with this product? I'm wondering if the performance and reliability is worth the premium price, or should I go with an OEM clutch replacement and just hope the original was a defective part.
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Brian_B

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Hmm.

I don't think having SAS makes a big difference on the clutch.

And I agree with you on worn clutch - and that this doesn't sound like that. It sounds more like you may have got oil or some other contaminate on the clutch surface, or the flywheel surface has got degraded signficantly. Will be interested to see pics of the clutch and flywheel once you get it out.

I don't have any input on aftermarket clutches though, hopefully someone else with more experience can chime in on that.
 

mpeugeot

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If you have to replace the clutch anyway, I guess that I would put in an upgraded clutch, but definitely not a Kevlar one - but an clutch that will tolerate being slipped and has increased clamping force.
 

albart

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From what i've read and my experiences coming from a world of shit boxes with manual transmissions. With the clutch being a dual-mass flywheel, it might be worth considering a single-mass flywheel while it's apart, due to the cost of a new dual-mass unit.
I did read (someone on here perhaps) had taken the plunge and swapped in a single mass flywheel, but it messed up the clutch pedal "feel".
something to consider.
Watching the thread for pics. at 5500mi on mine right now. Shifts great.
 

Lcubed

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22 Bronco Base 7MT Sasquatch 25k Miles

I was driving on the freeway and downshifted to make a pass when the Bronco went into a reduced power mode. I pulled over and turned the truck off then back on and the issue went away. About a week later I was going up a hill and when the Bronco started using boost the same thing happened. This time I noticed that the engine speed increased at a faster rate then the truck accelerated before it went into the reduced power mode. I connected to get the code read and confirmed the code specified clutch slippage. I can recreate the issue anytime now just by being in gear at pretty much any cruising speed and then trying to accelerate in the same gear. When boost comes on the clutch will start to slip. The odd thing is that it only happens in this specific scenario or when going uphill. Otherwise the Bronco can be driven normally with no issue. As long as there is no agressive acceleration, the clutch engages and shifts normally.

...

I have taken it offraod in the past and when in the sand or snow, where you have to ride the clutch a bit to keep from stalling, I have noticed a burning smell afterwards. Nothing that in my experience would indicate a complete failure, and only noticeable when standing outside the vehicle.
sounds like you glazed the clutch pads
 

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crenca

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About a week later I was going up a hill and when the Bronco started using boost the same thing happened. This time I noticed that the engine speed increased at a faster rate then the truck accelerated before it went into the reduced power mode. I connected to get the code read and confirmed the code specified clutch slippage. I can recreate the issue anytime now just by being in gear at pretty much any cruising speed and then trying to accelerate in the same gear. When boost comes on the clutch will start to slip. The odd thing is that it only happens in this specific scenario or when going uphill. Otherwise the Bronco can be driven normally with no issue. As long as there is no agressive acceleration, the clutch engages and shifts normally.

I've driven MT my whole life, I have never experienced a clutch go out like this.
This is a clutch that is worn out. It’s still creating enough friction under normal light-to-medium torque situations, but when your engine is in peak mid range boost there’s enough torque to get it to slip.

You’re just gonna have to replace it. I don’t know anything about these aftermarket clutches. I got my clutch too hot in an off-road situation where I thought I was in 4H but was in fact in 4A, I was using reverse quite a bit. Some odor and the pedal got soft. Only happened once however, I figured I shaved maybe 10 K of life off a clutch that should be good for 150 K…we will see.
 

Sparkie

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Clubs
 
22 Bronco Base 7MT Sasquatch 25k Miles
...
I have taken it offraod in the past and when in the sand or snow, where you have to ride the clutch a bit to keep from stalling, I have noticed a burning smell afterwards. Nothing that in my experience would indicate a complete failure, and only noticeable when standing outside the vehicle.
...
Yikes!
Riding the clutch while in Crawl Gear to "smell" level!? -- You are far more adventurous than me and my Bronco!

Any off-road trail where I thought I needed to ride the clutch in "C" was my indicator the trail would be taking me on "the road to ruin" for my Bronco or for me.
 

crenca

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Yikes!
Riding the clutch while in Crawl Gear to "smell" level!? -- You are far more adventurous than me and my Bronco!

I too was perplexed about his admitted driving style, and saying "have never experienced a clutch go out like this.", as it is after all the usual way.

Then I thought of my brother-in law. I rode with him once in his low powered Honda (small displacement 4 that is NA) and he road the clutch consistently - even using it to hold the vehicle on inclines at red lights. When I asked him the last time he replaced the clutch he said "never", and he had something like 80k on the thing!?! He also admitted he never driven a manual truck or high torque car, only compacts with NA 4's.

Maybe Honda makes clutches that can withstand this sort of driving style regularly?? I bet the majority of folks who get into a manual Bronco under a certain age (say 40) have only driven manuals in low powered compacts, as all high torque trucks/cars went auto only by 2000's (besides high powered Euro exotics, small number of cadillacs/corvettes, etc.).

Whatever the case, you can't drive the (boosted high-torque 4 cylinder) Bronco like that, the clutch is not engineered for it...
 

dgorsett

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Yikes!
Riding the clutch while in Crawl Gear to "smell" level!? -- You are far more adventurous than me and my Bronco!

Any off-road trail where I thought I needed to ride the clutch in "C" was my indicator the trail would be taking me on "the road to ruin" for my Bronco or for me.
Thanks for broaching the subject, I didn't want to be accused of being a hater and my Bronco has an auto so no room to talk but I will anyway :) . Previous 4x4s with manuals usually had granny gear but not always, seldom if ever smelled burning clutch. Use that crawler gear and low range. The poster running dunes from the middle east asking about removing upper gear limits in 4L in an auto knows.
 

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Brian_B

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Then I thought of my brother-in law. I rode with him once in his low powered Honda (small displacement 4 that is NA) and he road the clutch consistently - even using it to hold the vehicle on inclines at red lights. When I asked him the last time he replaced the clutch he said "never",
Clutch life is all about torque. They can live for quite a while in on an idle engine at a stop light. Start trying to do burn outs all the time though…

Throw out bearing is a different story though
 

0ne

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sounds like you glazed the clutch pads
On a slippery/loose surface rev to boost level in neutral, drop clutch and put some tooth back in the clutch surface 🤷‍♂️
 

JC2DR

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I have close to 50,000 miles on the original clutch. Mild off-road to be sure but no issues. Occasionally, after a trip with a lot of stop and go traffic there’s a bit of smell but it doesn’t last.
 

BadlandsA51

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Yeah, riding the clutch to the point of smelling it doesn’t happen very many times before the clutch is toast. It’s hard to imagine that being necessary if transmission was in crawl gear and transfer case was in 4 low. You can walk beside one of these running 2500 RPM in low/low.
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