Could Be Normal... Diff/gearbox Clunk

[devo]

hi guys, I have a BF mkII manual with 6000kms on it, from new it has had a huge amount of clunk, as in sometime at near zero throttle accelerating its impossible to change gears with out perfectly audible clunks and you can feel the diff clunk when you come of the clutch and back onto the throttle.

Also, in first gear if im just going slowly the gearbox whines rather audibly.

Sitting with the car parked in my carport, with brick walls and concrete roof, with the windows down, sometimes with the car turned off just pushing on the clutch can cause a very loud metal on metal sound both pushing down and releasing the clutch, not hard either, just on and off as you would changing gears.

I also seem to have a rattle, just driving along if I go accross repaired roads sometimes I can hear a very light rattle from the back, my dealer said the fuel tank filler tube was loose, and tightened it, but I dont think that was it as its still there now. My back seats seem to have a little rattle in them, has that been an issue before with the BF falcons? seems odd.

Anyway I keep taking it to my dealer and get told that they cant replicate the noises and that backlash and all the rest is well within the acceptable limits. That is s%&@ as I am good mates with the Service front desk guy at my dealer, and he has heard and knows the cars faults, and the dealer still wont act on anything. Im a former employee at the dealer so that could all be something to do with their unwillingness to act, but that's a story for another thread. Anyway, just wondering if what I have described above sound like something that needs fixing, I know there has been noisy driveline issues with the falcons before but this seems excessive.

[straughsberry]

Dealers ain't dealers - if you are getting the raw prawn and your dealer wont fire up the barbie, then find someone who will.

[devo]

problem is im in katherine nt... Hidden Valley Ford 3hours north, Centralian Motors like 10hours South... If I was back in Victoria I could just shop my car from dealer to dealer trying to get it done.

[watda]

I've been having the exact same kind of clunk from my diff. I have the same model T as you do.

Did you end up having this fixed?

I assume this is a problem "by design" rather than a fault so to speak. Every manual ford I've driven does a similar thing.

[R-SPEC]

I think the grinding from the gearbox at low revs is just roll over noise, they all do that and sometimes a thicker rubber can reduce the cabin noise or you can get it filled with foamy sh*t, but neither of them will completely eliminate it. The metal noise if it's a clicking noise could be the thrust bearing and the clunk would be the diff bush. The clunk they should fix under warranty because it's a known ffuk up of a design, but the bearing you may have to put up with, unless you get it looked at by someone who can tell you exactly what it is, then you can go and tell the service guys what it is.

Good luck

[watda]

What specifically needs to be fixed/replaced to get rid of the clunk?

[R-SPEC]

The sh*tty rubber diff bush. It cracks and loosens up and creates a slack which is the clunk/shunt you can feel...

It can be replaced under warranty if it's covered, which it should be, being only 6000ks old. Just go to the dealership and say the diff bush is rooted and you want a new one put in. If they road test they'll see the problem. They've replaced 1000s of them over the years, but no one can keep up with the changes in diffs that Ford have made with these cars, plus the BF MKII aint all that old, hence not many aftermarket or stronger options. They've changed the diff about 7 times in the past 3 models :o

[watda]

Sounds like a plan! Thanks for that

[R-SPEC]

You're welcome mate