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Manual transmission scraping noise / grinding sound

Mortonm

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I like others agree with the theory that either low oil or incorrect oil is the culprit. Starts as a minor then progress to a full time sound with some evidence of damage.
I posted my service summary a few oages back note how black the oil was after just 2300miles

Obviously there is some fairly significant inference somewhere
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I3lackRose

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I’m not sure this was ever posted here but an owner in a FB group posted that they had the TSB performed and the sound went away.

They included these pictures of the 5 and 6th gear having ā€œfriction weldā€ burn marks on them. Oil was also visibly discolored with metal. I screen grabbed those pictures of the gears. Not my content so I can’t offer much more of an explanation. This owner reported the dealer replaced these gears as well.

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Good info here. Thanks so much for dropping it here. I have not seen this yet. Now I want to know why and what's gunna prevent it on a rebuild/replacement. Others have reported a replacement trans and still the sound comes back. If it's fluid level related how could so many be underfilled and if it takes the slightest underfil to cause this amount of damage what does that say about the life of the vehicle or regularity we are going to have to dump these transmissions and check our fluid?
 

RobBob22

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Good info here. Thanks so much for dropping it here. I have not seen this yet. Now I want to know why and what's gunna prevent it on a rebuild/replacement. Others have reported a replacement trans and still the sound comes back. If it's fluid level related how could so many be underfilled and if it takes the slightest underfil to cause this amount of damage what does that say about the life of the vehicle or regularity we are going to have to dump these transmissions and check our fluid?
I think we all worry about this, I almost expect this to climb to the level of a recall once ford seems to really figure out root cause.

oil level/type is still pure speculation. Could be bad machining on these synchros that are getting replaced. Of course that could mean hit and miss replacements/repairs. Maybe the transmission manufacturer is aware and has already corrected tolerances. That’s of course is taboo if they made a change w/o implementing a new part number. But I also expect ford didn’t have shelves full or transmission parts, maybe to bad transmissions.
 

I3lackRose

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I think we all worry about this, I almost expect this to climb to the level of a recall once ford seems to really figure out root cause.

oil level/type is still pure speculation. Could be bad machining on these synchros that are getting replaced. Of course that could mean hit and miss replacements/repairs. Maybe the transmission manufacturer is aware and has already corrected tolerances. That’s of course is taboo if they made a change w/o implementing a new part number. But I also expect ford didn’t have shelves full or transmission parts, maybe to bad transmissions.
Glad I grabbed that 100k 8yr Ford Premium Care.
 

SPITmadFIRE

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At this rate, I may just drop my transmission fluid and throw in some Motul DCTF just to prolong the box’s life as much as I can. I’m already at 10k, and having my dealer tech open the transmission up to swap synchros just for them to grind away again feels more risky than waiting for a proper fix from Ford.

I’m not sure I’d even settle for less than a new gearbox entirely if the fluid is significantly contaminated. Who’s to say the entire box isn’t going to grenade at 40k from all the synchro glitter floating around in it?
 

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Mortonm

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At this rate, I may just drop my transmission fluid and throw in some Motul DCTF just to prolong the box’s life as much as I can. I’m already at 10k, and having my dealer tech open the transmission up to swap synchros just for them to grind away again feels more risky than waiting for a proper fix from Ford.

I’m not sure I’d even settle for less than a new gearbox entirely if the fluid is significantly contaminated. Who’s to say the entire box isn’t going to grenade at 40k from all the synchro glitter floating around in it?
That's really my concern isn't getting this sorted now I just don't want to be worrying about this foe the life of the vehicle.
 

SPITmadFIRE

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Having gone through the Focus RS head gasket and timing chain cover sagas, I recommend everyone stand firm with their dealerships and make them replace the whole gearbox under warranty if they drop the fluid and note any sort of metal shavings at all. If they dropped the engine oil pan and found metal shavings, they wouldn’t bother messing around with replacing individual parts — they’d swap the whole damn short block.

Only when @Ford Motor Company starts to realize swapping entire transmissions every 10k miles is getting expensive will they actually put out a proper fix.
 

Mortonm

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Having gone through the Focus RS head gasket and timing chain cover sagas, I recommend everyone stand firm with their dealerships and make them replace the whole gearbox under warranty if they drop the fluid and note any sort of metal shavings at all. If they dropped the engine oil pan and found metal shavings, they wouldn’t bother messing around with replacing individual parts — they’d swap the whole damn short block.

Only when @Ford Motor Company starts to realize swapping entire transmissions every 10k miles is getting expensive will they actually put out a proper fix.
The problem is that replacing the transmission right now doesn't garauntee a fix, just had mine done and the sound is back.

They will need a new version of a part to fix the issue. Until then they are just kicking the problem down the line
 

SPITmadFIRE

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The problem is that replacing the transmission right now doesn't garauntee a fix, just had mine done and the sound is back.

They will need a new version of a part to fix the issue. Until then they are just kicking the problem down the line
Yes, understood — but if we don’t go in for expensive fixes and make Ford warranty cough up the cost for new components, Ford will continue to kick that can. I’ve gone from the ā€œwait it outā€ camp firmly into ā€œmake @Ford Motor Company buy me a new transmission every time I hear a grinding noiseā€ mode because that’s the only way they’ll figure their shit out.

Back in the RS head gasket days when they installed the wrong part altogether, they denied denied denied until the warranty claims became overwhelming. Only then did they start aggressively testing and replacing every single engine. It’s their liability, we should be ensuring they feel the true cost of the issue so they resolve it promptly.
 

Mortonm

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Yes, understood — but if we don’t go in for expensive fixes and make Ford warranty cough up the cost for new components, Ford will continue to kick that can. I’ve gone from the ā€œwait it outā€ camp firmly into ā€œmake @Ford Motor Company buy me a new transmission every time I hear a grinding noiseā€ mode because that’s the only way they’ll figure their shit out.

Back in the RS head gasket days when they installed the wrong part altogether, they denied denied denied until the warranty claims became overwhelming. Only then did they start aggressively testing and replacing every single engine. It’s their liability, we should be ensuring they feel the true cost of the issue so they resolve it promptly.
Yes I agree. I've had mine back since the transmission was replaced for 3 weeks. It goes in on the 9th for whatever they decide to do next, I assume the TSB
 

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I know its not a scientific but that poll in the other thread is telling. Almost 75% are reporting the noise. I'm surprised this issue isnt being covered anywhere outside of the forums. I tried tweeting at Mr Levine a few times a while back but go no response. We should promote the <blank> out of this until it gets publicized and they have to respond.
 

Ducati1098

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I recommend everyone stand firm with their dealerships and make them replace the whole gearbox under warranty if they drop the fluid and note any sort of metal shavings at all.
Unfortunately that’s not up to the dealership to decide. They have to abide by why what Ford directs them to do. And now that Ford has released a TSB, they won’t be replacing whole transmissions for this concern, except in very rare instances. Dirty fluid, or metal isn’t enough to replace a whole unit.
 

Mortonm

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Unfortunately that’s not up to the dealership to decide. They have to abide by why what Ford directs them to do. And now that Ford has released a TSB, they won’t be replacing whole transmissions for this concern, except in very rare instances. Dirty fluid, or metal isn’t enough to replace a whole unit.
I do find it weird they authorized my replacement so quickly. My dealer never even asked, they just called and said the new one be here tomorrow and a couple days after that you will have it back.

This was just the week before the TSB though
 

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I do find it weird they authorized my replacement so quickly. My dealer never even asked, they just called and said the new one be here tomorrow and a couple days after that you will have it back.

This was just the week before the TSB though
This is most likely because they already knew about the issue, but didn’t have a repair yet. Now that the TSB is out, they’ll want them all repaired.
 

SPITmadFIRE

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Unfortunately that’s not up to the dealership to decide. They have to abide by why what Ford directs them to do. And now that Ford has released a TSB, they won’t be replacing whole transmissions for this concern, except in very rare instances. Dirty fluid, or metal isn’t enough to replace a whole unit.
Those same dealerships will not want to get paid 9.6 hours for a job that takes significantly more time, and requires experience reassembling a transmission. I’ll let them decide whether they’d like to report ā€œfound transmission fluid with glitterā€, or ā€œgrinding noiseā€ to their warranty rep šŸ˜…
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