5th Gear Crunches Who Has Had This Problem?

[joes]

Hi,

Just started to get the 5th gear crunch - 39,500km for a Nov-2003 build.

The crunch occurs when doing 100km/hr @ 3000rpm.

When doing a slow 4th->5th change, that is let the revs drop from

3000rpm to 2000rpm before changing, there is no crunch.

All other gear changes are fine.

Going through this thread, several people have had ther gear boxes

replaced.

Do you think I should push to get the 5th gear synchro's changed or

the whole gear box changed?

Have others had hassles with ford dealers, given they can say the

recommended change into 5th is at 75km/hr ?

If it is left as is, how bad will the crunch get ?

Cheers Joe

[mickq]

Watch the gear box oil change trick. If they are dodgy they will use thicker oil - it tends to reduce the perception of problems by making noises disappear, yet doesnt fix the underlying problem. (People often pull this trick just prior to selling their car).

Cant see why a dealer would do that though, unless Ford had told them to initially try thicker oil to see if it helps prior to a gearbox swap under warrantee.

I wonder if there is some truth to what people say re 5th to 3rd swaps being a contributing factor.

I thrash the crap out of my car, but I also know how to use a gearbox properly. I havent had a problem except every blue moon it crunches into 2nd or jumps out of 2nd. (I use second a hell of a lot under full accelleration). Otherwise its as quiet and reliable as day one.

I certainly dont understand how people could go through multiple gearboxes in short succession. Im not aware of any trend of dodgy boxes. Bad luck or bad driving. Id love to watch them drive and see if I can point out something they are doing that's contributing.

People shouldnt do 5th --> 3rd gear changes. Sure you can, but you shouldnt. You will notice even race car drivers wont generally do it either, or it they do its with perfect double-clutching.

If you have to go 5th to 3rd, I recommend people go:

Clutch in

Move gear stick into 4th. Keep clutch in.

Move gearstick into 3rd.

Let clutch out.

Its much better than a direct change.

Ideally they should double clutch into 4th then into 3rd. You can do that just about as quick as a 5th-->3rd direct change anyway.

Going direct from 5th to 3rd will often place the syncromesh under an unusually high load as the speed differential it needs to cope with is significantly higher as you are jumping a gear. The result is the syncro wearing out faster.

Edited 01/12/04 01:30 AM by mickq

[Guest TRACK]

My car crunched into 5th at 100km +, and only had 10,000km on it. It's a June 03 build. You guys have got it easier now, as Ford have now seen this many times before. I had all sorts of issues with them trying to get my box replaced.

On 2 separate occassions, the dealer rang me back saying they could not replicate the crunch. I told them it does it everytime at 100+ when I dropped off the car, he told me they tested it only up to 75km/h. Later that day the dealer rang me back and said the car was tested to 120km/h and no crunch, and the mechanic didn't want to test it any faster as he was in a 50km/h zone. What a load of ! I doubt the car ever went over 75km/h.

The following day I took said mechanic for a run down the M5 Motorway, and what do you know it crunched EVERY time. I still had to argue for a new gearbox!! They wanted to change oils, add compounds, etc.

The crunching box basically refused to got from 5th to 3rd, even double clucthing, it was really a chore, the new box is much better (still a chore) and has 47,000km on it.

I don't baby it, I just drive it as required, if it fails Ford can put another one in!

I've often thought about installing a data logger in the car and just watch what Ford actually do (good, bad or at all), when test driving my car.

[CFlat]

Oi all,

Mines a May '03 build. Had first new gearbox at 12000km, second at 12600km (yep 600 k's) third at around 27000km and then just a top gear "set' at about 38000km. They won't replace complete boxes any more, just the real dodgy bits. Mines at 47000km now and still going OK. Oh, went to adjust my drivers side rearview mirror on the way to work this morning and the little twirly knob fell off! Now that's what I call "remote adjustment", it's in my pocket!!

Ciao

Steve

[Guest TRACK]

You've just got to love your Ford. NOT!

[bugeyedcreepy]

I had a fifth gear crunch from purchase (April 2004). I told my service guys about it and they ordered in and replaced a fifth gear set and I've had no problems since, now done 40,000k.

[profrat]

Shheesh. I am sorta glad to see this thread because my 'T' has the same problem ( but not glad to have it!). First noticed it changing from 3rd to 5th and then 4th to 5th at higher speeds (120+) . I mentioned the 3rd to 5th problem to the dealer at the 30,000 service. He said it was probably just normal when skipping gears but they would check it out. When I picked it up he sounded genuinely concerned and told me the mechanic who test drove it said it was really bad from 4th to 5th and he would report it because something would have to be done. He also said they didn't like the 3rd shift gate from any gear and that it was not good enough. I had a chuckle at that one because I always knew this but thought they would say it was 'normal'. Looks like I might get a new 'box but I hope this does not become a continuous repeating problem.

Wonder if they might just slip in a new 6 speed to fix it for good............ I'd like to see that!

[RAPHOON]

Shheesh. I am sorta glad to see this thread because my 'T' has the same problem ( but not glad to have it!). First noticed it changing from 3rd to 5th and then 4th to 5th at higher speeds (120+) . I mentioned the 3rd to 5th problem to the dealer at the 30,000 service. He said it was probably just normal when skipping gears but they would check it out. When I picked it up he sounded genuinely concerned and told me the mechanic who test drove it said it was really bad from 4th to 5th and he would report it because something would have to be done. He also said they didn't like the 3rd shift gate from any gear and that it was not good enough. I had a chuckle at that one because I always knew this but thought they would say it was 'normal'.  Looks like I might get a new 'box but I hope this does not become a continuous repeating problem.

Wonder if they might just slip in a new 6 speed to fix it for good............ I'd like to see that!

I think there is little chance of a six speed but hey if you don't ask..... :lol:

My car currently has gearbox #3 and looks like this one is working OK.

Ford (ION = gearbox supplier) will want to try for a synchro change, then a 5th gear and syncro change before they autorise a new box UNLESS you kick and scream and have a good dealer to look after you.

Good luck with it as I know how annoying this issue can be.

[alanb007]

Well, My T has just developed the crunch going from 4th to 5th at over ~100kph

I thought it was just me being lazy with the clutch, but it still did it when I made sure the clutch went to the floor.

The car is 6 months old and is just about due for the 15k service and hopefully I won't go through the hoops to convince them I have a problem.

From reading the threads, I guess I have been a bit naughty with my gear changes. I happily fang it in 1st and 2nd up to the speed limit and then cruise into 5th. Also, when preparing for a squirt on the juice, I regulary drop from 5th to 3rd.

There were no warning signs. It just started one day.

Wot a bummer.

For what its worth, it has also developed the power steering judder at low speed and an idle that is fine and then will drop to 500rev and speed back up (in neutral, no load)

I can live with the idle and the judder, but the gearbox is a real downer. You can't show off with the speed with someone in the car when you crunch through the gears! You look like the apprentice!

Alanb007

[profrat]

I reported my 5th gear crunch again last week at the 45000 service. When I picked it up friday evening the front office guy said he had been told that they had ordered some parts to fix it and they would get it back in next week. It does not sound like I am getting a new box. Not sure what to make of this. I will talk to the service manager on Monday. Should I be pushing for a new 'box?