DIFF CLUNK - Combined Approach

[Buf-Phoon]

Dealer rang today and left a message to say , that after 6 months my new diff has arrived. Now, given JBs horror story do I book it in or leave it and put up with the whine at 90-95ks :banghead:

[Henry]

Just curious, have any of you guys tried changing your diff oil and possibly your gearbox oil?

While I have backlash and clunking in mine, I can drive around it. A very reputable driveline specialist has recommended I try changing the oil in these 2 components, cos he has seen impressive improvements in terms of reduced noise and clunking and a smoother shift.

I will be attending to these things over the next couple of weex, so I will let you know how I go.

[Trumpy]

Dealer rang today and left a message to say , that after 6 months my new diff has arrived. Now, given JBs horror story do I book it in or leave it and put up with the whine at 90-95ks

Whatever you do, make sure that they have a working tailshaft balancer in their hands before they do your diff. Dont take no for an answer!

[JB]

Oh yeah, Trumpy is dead right, under no circumstances let them change your diff without the tailshaft balancing tool, TRUST ME!

Henry, already a number of steps ahead of you mate. Gearbox oil has had 3 different types in it, no difference whatsoever, diff well everything has been tried, here comes diff number 4 :banghead:

[Buf-Phoon]

Thanks guys , you are absolutely correct. I will also want to see the balancer, not just drop the car off, take their word for it and have Bozo the apprentice work his voodoo

[ZAP]

Well I went to the Diff specialist, I thought he also did gearboxes, but he did not have the equipment (dyno) to test the gearbox. He said the diff is "not bad", but it did have some backlash, but the gearbox was a good clunker, as he test drove the car and was shocked how bad a car with 8,000km on the clock was.

They said the only way to fix the clunk was to pull the gearbox out and replace the non spec parts, shim the diff and check the unijoints.

I have been referred to a mechanical engineer that can do a expert opinion report that would be required if it gets nasty.

I do not suggest that anyone take on Ford directly via legal means, use the consumer law (Dept Fair Trading in NSW) and let them pay the legal bills. Threatning Ford with ACA or TT will not bother them much as these are just crap shows that nobody remembers. They just want raitings and could not care less about your problem or if it gets fixed, only if it makes a good story. Forums like this would do 10x the damage than ray martin trying to make a boring story interesting.

[JB]

Hey Zap, is he indicating that the clunk is actually generated by the gearbox and not the diff? Or is it a combination of both?

Interested to see how you go with all this, so please keep us posted.

[Mondie]

that's about what l expected Zap. Both diff and gearbox needed to be opened, some components have to be replaced and of course there is then the warranty implications. It could easily turn into a $1500 repair

[hypnodoc]

that's about what l expected Zap. Both diff and gearbox needed to be opened, some components have to be replaced and of course there is then the warranty implications. It could easily turn into a $1500 repair

I am beginning to wonder how much the electronic throttle is responsible for the clanking, the reason is that I changed my T/Body up to 80mm and noticed much less tendency to shunting and clanking from the bum, I thought it must be in my mind, but I have now gone back to the 75mm T/Body and straight away the shunting and clanking has got noticably worse, after 5 months with the 80 I can now make a fair comparison, weird perhaps, but true nonetheless

[ZAP]

I do know that Ford have apparently "fixed" most of the problems. For the people with manuals that have had a PCM upgrade will now notice that when they change gears the car revs the engine once the clutch is released. This is how ford have reduced the clunking as when you release the clutch the engine has more revs and thus will take up the slack quicker. I am now sure that we will all be seeing premature clutch wear as the clutch will be engaging while the car is still high in the revs. I will be telling Ford where to stick their clutches are not covered under warranty when I claim my first clutch in under 40,000km. Whould be interesting .