Gearbox Issue

[Karnyge]

Hey guys,

New member, bought a dealer used manual 08 fg turbo sedan about a month ago, absolutely love the thing, I started noticing particularly when the car is cold when engaging and releasing the clutch in first and second, a rattle sound quite a quick one, hard to explain, I understand that these boxes are quote clunky etc, but mine seemed fine, when I tap the accelerator in a higher gear I noticed a banging sound too coming from the same area, my mates thought these sounds particularly the gear changing could be thrust bearing or clutch issues, long story short I just got the car back from the ford service centre and told there is nothing wrong with it, they had the box out and test drove it, the rep tells me the roll over noise is common, only thing they did was update the ecu with the latest software, upon getting the car and diving home the problem is even worse, I notice it no matter what gear how fast etc every time I hit the clutch I hear it a clunk what ever, even down shifting, got home and called the rep right away he keeps insisting it's normal, I said how when it wasn't like this when I got the car and before I dropped it to you it wasn't this bad, I could've lived with the issue while it was cold and only down low but not now when it's hot and every time, he has said to bring it back and take the foreman for a drive but he will say it's normal?

Sorry for the rant, what do you guys think? Cheers

[Pedja]

BRO!!!!!!!!!!! I HAVE THE SAME PROBLEM!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!@@@@@@@@@@@@@@@@@@ and its only done 12000kms and its bran dnew 2012 fg xr6 na....manual.

wtf do we do, I took it to them and it only got worst..

[AdamIan69]

Yep stay with them mate, ask to hear another manual in there workshop and compare for yourself. You checked the oil level? As said before it does sound like roll over noise. You can also buy an oil sample bottle and get the oil analysed. They will tell you what types of metal is wearing and the metal count. Your local caterpillar or Komatsu do it for around $20.

[Karnyge]

It is far worse than before I took it to them and this issue has been progressive when I got the car it was unnoticeable, the car has only done 89000, I get the call to go and pick it up and I asked about it and I get told all noise are fixed quiet as anything, what kind of potatoes are you pricks running in your ears... I had a pre purchase inspection done and the mechanic noted a small noise while cold from the clutch and just watch it, I have the report and there is nothing of which I'm hearing now noted, I'm confident he would drive it now and say that definitely wasn't there before, I'm getting a vibration now while in neutral which wasn't there before either which goes when engaging the clutch

[Karnyge]

Also I'm finding it hard to get into fourth that too was definitely not an issue prior to taking it to be looked at

[old_mate]

what city/town are you in?

[Karnyge]

Sydney

[BRK]

It is a bit of a guessing game but if the hub springs in the driven plate on the clutch are broken you can also get these sorts of noises and hard gear changes.

Roll over rattle is generally more pronounced when the trans is hot - just from normal driving - and you have the aircon on with the car stationery in neutral. You do get more noise as the engine management system maintains idle speed when the aircon cuts in. However, if you raise rpm to about 1000, roll over rattle should disappear. According to the Ford dealer that I took by BF to, rattle is common in these cars but they do occasionally replace under warranty. Some dealers will say the tr6060 in FG or T56 in BA2 and BF is a "truck gearbox" - urban myth. They have quite high torque capabilities and that is why they get tagged that way.

Speaking only about the T56 which uses dex3 as a lubricant, there are no fluid additives available to quieten the gearbox however, I do know one Ford Dealer in WA suggested they had limited success with one of the Redline products - it is compatible with the T56 - but it is costly. If you raise the viscosity of the gearbox oil you will find cold changes really hard and the manufacturers - Tremec - will always advise you to use dex3. Some people have overfilled the trans by as much as one litre to solve the problem and I went that way and used 500ML over the capacity; it made no difference. What is interesting about this issue ( but doesn't help) is that in a few conversations with the Expensive Daewoo crowd the T56 in the Late model camira does not seem to have this issue.

Saving for a few things at the moment but next round of mods, I am going to get the workshop to fiddle with the idle speed and see if we can find an idle rpm point that does not produce this.

[Karnyge]

Thanks for the info, the biggest annoyance for me is that is was no where near as bad as it is now they have played around with it, I just can't accept their bs when I have proof it didn't do this beforehand, definitely didn't have issues getting it into fourth it was butter second sometimes when it was cold, the aircon was set to auto 22 and there was no cool air flowing at all barely any air, only when I set the temp down low it comes on, this is something else that wasn't an issue, the fact when I went to pick it up and was told it's in the car park when it wasn't and the car couldn't be found for 10 minutes makes me wonder

[ms700]

Makes you wonder what.....

someone forgot where they parked it?