ASM drops clutch too quickly/roughly and stalls

[sjmcl]

I've just bought a secondhand 2002 Transit 350L, Engine D2FA, 2.4 DuraTorq Diesel, 238,000 km on the clock. The previous owner assured me he never had any problems with the gearbox, yet I'm just finding out he may have been covering up..

The van drives very nicely and shifts gears smoothly, except occasionally when taking off. I believe it is dropping the clutch too quickly, usually even before the revs go up, which then causes the van to stall. Most awkward in city traffic!

I found a way to prevent it from stalling though. When stopped at the lights, I put it in neutral, and when just about to go I rev it up (while still in neutral) and then quickly press the D button to put it into gear/auto. I've never had it stall on me using this procedure, but it is very awkward. Sometimes I can still hear and feel the clutch being dropped a bit roughly but because the engine is already revving up enough it does not stall, it just gives a little knock or jerk. I've never noticed the same rough gearbox changes at any other speeds and gear changes, only when taking off.

Does anyone recognize these symptoms and is able to point me in the right direction?

Thank you.

PS : I'm not a mechanic by trade, but I have always been able to service and fix my own vehicles, including swapping an EPIC fuel injection pump for a Bosh mechanical pump (best thing I ever did to my previous Transit!!).

[Punto443]

Hi welcome to the forum.

I don’t know much about these asm’s. However most seem to have problems are down to the high pressure pump or relays

[Punto443]

Although this thread doesn’t sound too far away from your symptoms?
viewtopic.php?f=2&t=169661&p=1516205&hilit=Asm#p1516205

[sjmcl]

Thanks Punto. I saw that thread but I was hoping to avoid trial and error and pinpoint the exact problem. I got another possible clue this morning. When I took off down the road (in automatic) it would not shift into second gear. I had to press the manual button on the steering wheel to put it into second gear, and then press the D button to put it back into auto. After that it would behave again.

Also, my previous trick of revving it up in neutral first still works, but I've had a few times where it would almost stall and jerk a few times, even after revving it up. Can't be healthy for the clutch and gearbox.

In the long run I'm really keen to convert this to a full manual, but I have not been able to source the parts (and instructions) I need for it.

[bambi mk 1]

ASM = another silly mistake