So I took my 1996 F-350 to the garage to examine a shaking and very rough idling at times but not always. They told me the flywheel and clutch needed replaced as I suspected so didn't blink to okay the repair. After they were done they told me the original flywheel for these trucks were not available anymore but they put a heavy duty one on. I said okay as work was already done and thought things would be fine. Well now when I let the truck basically pull itself in first gear there is a loud moaning or rubbing sound and this also happens in 4th gear as you are off the gas and coasting at about 35-40. Driving up through the gears or when on the gas I don't notice it but definitely hear it as described above most. I took it back immediately and mentioned this and they had it for 3 weeks basically did nothing then told me its because this isn't the original flywheel so while annoying this won't hurt anything. Has anyone replaced a cluthc and flywheel recently in one of these and experienced this? The guy tried to tell me drive any manual and you'll hear similar noises which is complete BS as all I have and ever had are manuals and none of them make this noise before or after replacing clutches. And this was a Ford dealership to boot which I know bad choice but figured they would at least do it right since not a lot of folks will work on diesels near me and they have had to see these come in as there are still a ton of them on the road. Anyone have any ideas on what that rubbing grinding noise may be from cause Ford sure didn't know and if it is something to worry about?

 

Gear rollover. 100% normal, you just can’t hear it with a dual mass flywheel. The ZF is a clunky heavy truck transmission. Drive a manual truck from the 60’s, they really made some noise. The trick to less noise is more RPM. Don’t lug it, and get on the clutch a little sooner when stopping. You’ll get the hang of it.

 

Thanks I have gotten used to it and don't lug it but definitely running in lower gears through town to keep RPMS up and getting on the clutch earlier when coming to stops. Hate that I have to change the way I drive but it is good to hear this is normal and not doing any damage to the truck. Thanks for the reply