Clutch & Cylinder Failed at less than 900 miles. Dealer denied warranty claim

[gatorjohn]

OP, you seem to have the means... while you are waiting for Ford to respond, just fix it yourself, or an independent shop, and keep going. A clutch R&R is no big deal, maybe you will find something in the process. Document everything for future resolution with Ford.

You can turn this into as big of a cluster F* as you wish, which keeps your Bronco on the lift, and adds grey hair to your head. Your call.

Good luck.

I do think this is probably the best take. I am fortunate enough to be able to cover it out of pocket, but I would like to at least get the Ford Corporate disposition first and give them the opportunity to make it right before I have to escalate further through legal channels. My other issue is the quote the dealership gave me... almost $8k!!

I could take it to another shop, but that is also a headache since the Bronco is disassembled at the moment. So it's kind of of a matter of choosing which headaches I want to endure.

These posts make me nervous to drive mine off road far from serviceable areas. I picked up mine with 200 test drive miles so who knows how bad it was treated (super good price though). I can’t believe a clutch can abused enough to burn it at 900 miles. I’ve had a Nissan Frontier for 20 years and done all the “bad” things like rocking it 1-R-1 out of snow every year and frequently driving in stop go traffic and starting from stop on steep hills. Lots of other problems but the clutch is not one.

It is unfortunate, but I do really think I have a manufacturer defect/issue with assembly or similar. It seems many 7MT Broncos have had no issue, even with some mild abuse. I didn't make this thread to scare anybody or say that every single Bronco has this issue, because I don't think that's true. Unfortunately, I'm the 'lucky' one that drew this card and now has to deal with it...

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[BadlandsA51]

It looks like the lining is gone from one side of the clutch. That is usually caused by accidentally shifting into the wrong gear, going for 5th and hitting 3rd. As soon as you go into the wrong gear the clutch disk spins up to the RPM the engine would be at in that gear at the road speed you are currently traveling. During my time at Ford I saw this several times. I saw a Focus that was downshifted to second coming down an exit ramp at 65 MPH. He was going for fourth. He let the clutch out and totally grenaded the engine. Rods hanging out of the block, there were no pistons left in any bores. I calculated that the disc was doing about 14,000 rpm when he let the clutch out.

 

[11811]

If the clutch was built wrong or there was a foreign object inside, one would think that you would hear, feel or smell something odd before it failed like that.

 

[Redlaw]

You said the slave cylinder failed but didn't describe how..
If the slave cylinder was sticking and not allowing the throwout bearing to fully disengage then it could be riding the clutch even if your foot was off the clutch pedal.
If this is the case then this condition could burn the clutch. I would push back on the dealer with this..

 

[I_Fly]

Clutches are a wearable part. This makes the decision of warranty vs. not a bit less defined. At the moment it is the dealer making the call. I would call Ford Customer Care and push back on the dealer. Something does not add up. If they aren't willing to work with you, take it to another dealer. No need to feed the gremlins.
Some other thoughts.
Dealers get graded on a number of things. Warranty vs. customer paid repairs is one of those. No need for you to pay because they have gotten themselves into the hot seat.
Also, find out if they do transmission work themselves. Many dealers are short on specialists. They may be sending it out anyhow. That would cause them all sorts of issues with a warranty claim (they should have someone qualified).

 

[GreyZ]

My other issue is the quote the dealership gave me... almost $8k!!

I could take it to another shop, but that is also a headache since the Bronco is disassembled at the moment. So it's kind of of a matter of choosing which headaches I want to endure.

This is the most absurd part here. That is INSANE for a clutch and slave R+R. Do they have a break down of that price. You could pull the engine out and replace the clutch on a stand for that cost.

 

[Willub]

My other issue is the quote the dealership gave me... almost $8k!!

Uh, what?

I’d think a clutch job at a dealer would be 1,500 to 2k.

 

[broncobase1]

I'm in disbelief.

I've driven a manual most of my life. One of those cars was a 93 Eddie Bauer Bronco 5 speed that went 200k miles on the original clutch.

I've got a newer SuperDuty truck I love, and I loved that old 93 Bronco, but it seems the modern for manuals are just not durable, or have any longevity. Will be the last Ford I ever buy.

Okay Okay Okay if the warrantee was declined at 900 miles there is more to this story. If you revved the engine and did a clutch dump you deserve to not to have it covered and should have to pay a big fine in addition. Yeah -- I've seen people do this testing driving a brand new car. Talk about stupidity.

 

[broncobase1]

I realize nobody is going to say they can't drive a manual great, but I've had 4-5 manual cars / SUVs / Trucks over the years, and never had a clutch replacement at less than 150k miles....

For one to go out on a brand new car in less than 1k miles to me is just bonkers -- even if they were a terrible driver. I'm not disputing the clutch is burnt up, but under 900 miles with a seasoned manual driver without some kind of manufacturer defect?

That isn't just a defect that is major abuse. If it wasn't you it was somebody else, probably the idiot who test drove the Bronco before you bought it.

 

[cbrenthus]

I understand that's how it works from the Dealer / Ford corporate perspective.... but Magnuson Moss warranty laws. are the opposite: Ford has to have positive proof that it was user error.

They don't "have" to do anything until you get it in front of a judge, and here is what that looks like:

https://www.tacomaworld.com/threads/ffs-lets-all-stop-referencing-the-magnussen-moss-act.609911/

Normally I post this story when people complain that the dealer / manufacturer has to prove the 90 psi supercharger blew their engine, because the purpose of MM was to protect people that use aftermarket oil filters and such.

Although, you haven't mentioned if you have any mods?

 

[gatorjohn]

They don't "have" to do anything until you get it in front of a judge, and here is what that looks like:

https://www.tacomaworld.com/threads/ffs-lets-all-stop-referencing-the-magnussen-moss-act.609911/

Normally I post this story when people complain that the dealer / manufacturer has to prove the 90 psi supercharger blew their engine, because the purpose of MM was to protect people that use aftermarket oil filters and such.

Although, you haven't mentioned if you have any mods?

No Mods.

And of course they may not do anything until they get in front of a judge practically. That doesn't change the law. The law is still the law whether they decide to wait until the government makes them present their evidence and enforce the law.

Just because I don't get a speeding ticket if I speed when no one is around doesn't mean I'm not breaking the law.

 

[gatorjohn]

This is the most absurd part here. That is INSANE for a clutch and slave R+R. Do they have a break down of that price. You could pull the engine out and replace the clutch on a stand for that cost.

Clutch, Flywheel, Slave Cylinder, Pressure plate parts quoted at ~$4k with labor almost the same.

 

[michelle227]

I had one of the first manual Jaguar F-Types produced. The Gen 1 clutch was from the Volvo parts bin and was a noted issue such that Jaguar replaced several of those 440 with a beefier clutch. I later got a second replacement because, at ~1200 miles, the flywheel wasn't done, contributing to the second failure.

But we dont have a 'known issue' with the Bronco. I've got one that I ordered, so ive been pretty much the only one behind the wheel. Like you, ive driven many manuals in my life, having learned on a Volvo 1800S with no synchros...

This failure didn't just happen overnight. The service staff know that as well. Missing them off at every turn wont help nor will misquoting the law.

 

[GreyZ]

Clutch, Flywheel, Slave Cylinder, Pressure plate parts quoted at ~$4k with labor almost the same.

A southbend kit + slave is less than 2k for better than OEM quality. At the very least I wouldn't put the oem clutch back in over a southbend HD kit.

 

[Bronco21Maybe]

Dang, it looks like someone left an SOS pad in your clutch.

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