Animal169 Posted February 1, 2009 Report Posted February 1, 2009 Hi all, Hopefully no-one has had an expensive version of my problem. Just over the last few weks, my gearbox has become very noisy, it's not the O/S stub drive shaft, in fact I've isolated it to the input side of the box as the pitch of the noise changes with engine revs rather than road speed. I'm thinking it could be a bearing on the input shaft?? If anyone's come across a similar issue I'd appreciate your experience and remedies. Worst case I've found a supplier that can get me a recon box for Quote
Bigjeeze Posted February 1, 2009 Report Posted February 1, 2009 WHat model do you have - Year etc? Quote
gregers Posted February 1, 2009 Report Posted February 1, 2009 is this any help big?Vehicle Type: Galaxy LX 1.9 TDI PD 115 Quote
Animal169 Posted February 2, 2009 Author Report Posted February 2, 2009 Yes, sorry, should have said, 54 plate for the final bit of info. Cheers. Quote
Bigjeeze Posted February 2, 2009 Report Posted February 2, 2009 I have no real idea what the problem is - but as for changing it on the roadside - I would say that undoing all the necessary bits & pieces is OK but you do have to remember that you need either an engine support bar or two jacks because once you have taken off the gearbox mounting (under the battery) then you need to support the engine & gearbox . Then once you have it undone you need to lower the whole thing - down slightly (gearbox side) to get the box off - it needs to be rotated slightly to get if off -then beware because it is extremely heavy!!. I couldn't lift it on my own (without giving up my masculine voice) - I needed my son to help me - It probably weighs around 100Kgs +. Apart from that it's fairly straighforward. Quote
Animal169 Posted February 3, 2009 Author Report Posted February 3, 2009 Well, at least replacement doesn't sound too bad if it needs it, I'll do some more digging, it'd be nice to think my dealer could diagnose, but they're good at servicing and that's about it! Cheers. Quote
Animal169 Posted February 4, 2009 Author Report Posted February 4, 2009 OK, new update, the car is now vibrating under acceleration, this does not look good!! I fear a complete failure is coming on!! Quote
Animal169 Posted February 4, 2009 Author Report Posted February 4, 2009 Right, I'd appreciate a little more help here, from research on other PD engine forums (audi, skoda, vw) could it be the flywheel???? seems to explain most of the symptoms?? Quote
seatkid Posted February 5, 2009 Report Posted February 5, 2009 DMF - Dual Mass Flywheel. Common failure. Quite expensive. Certain dates of VW Seat Models had a recall with free replacement but AFAIK Ford have refused to acknowledge any problem. Try a search. GSF stock DMF's at a reasonable price IIRC. Quote
Bigjeeze Posted February 5, 2009 Report Posted February 5, 2009 I replaced my clutch at Christmas - The DMF was retail Quote
Animal169 Posted February 5, 2009 Author Report Posted February 5, 2009 Well that's better than a gearbox replacement, would the DMF cause a noise that sounds like a growl? the vibration seems right, at neutral throttle while driving there is no noise at all, and there's nothing obvious when in neutral gear, the growl is when either accelerating (which has now been joined by vibration that seems to coincide with cylinder firing) and decelerating where the growl takes on a type of pulse, it's all linked to engine revs rather than road speed. My Fraud dealer is going to take a look tomorrow, but I'm trying to narrow it down as far as I can now. Thanks for all help so far! Quote
Triple Trouble Posted February 5, 2009 Report Posted February 5, 2009 There was a recall on the DMF some 3 years ago, certainly on 130bhp models, not sure about 115's. Local fraud will no doubt confirm. Best of luck for the cheapest solution!! Quote
f0ster Posted February 5, 2009 Report Posted February 5, 2009 hello recomend you put it up on a wheel free hoist if possible and run it in gear while you listen in from below to see if you can spot where the noise is comming from, a stethoscope for motor vehicles is handy in these situations, Quote
Animal169 Posted February 6, 2009 Author Report Posted February 6, 2009 Ok, then, latest update!! I'm starting to get very frustrated with all of this, I took my car to the Fraud dealer, they're normally pretty good, well they're better than Furrows who own most of the car dealerships within a 25 mile radius!! They diagnosed it as a gearbox problem as my flywheel is a solid one!! Ford's gearbox price by the way is Just over Quote
Animal169 Posted February 6, 2009 Author Report Posted February 6, 2009 Ok, then, latest update!! I'm starting to get very frustrated with all of this, I took my car to the Fraud dealer, they're normally pretty good, well they're better than Furrows who own most of the car dealerships within a 25 mile radius!! They diagnosed it as a gearbox problem as my flywheel is a solid one!! Ford's gearbox price by the way is Just over Quote
seatkid Posted February 6, 2009 Report Posted February 6, 2009 So, next question, is there any way of inspecting/viewing the DMF without taking the gearbox off just to see if I can see any issues??? I doubt it, but you could try this. With car in top gear (6th), jack up front of car one side, and see if you can turn the wheel by hand without the engine crank moving. The wheel should only turn a few mm at most. Any larger slop would indicate a problem I think. These are just my thoughts based on what I think a DMF is i.e a double sandwich flywheel with rubber bonding between the two bits. When they fail, the rubber breaks allowing excess movement between the two. As its only one or two blocks of several that fail initially, thats what leads to vibration. If you're going to fix your car yourself then you will have to remove the gearbox anyway. Then you can make a full inspection and decide. Odds on its a DMF fault as they are know common failures. AFAIK all Mk II diesels have dmfs. Quote
Animal169 Posted February 6, 2009 Author Report Posted February 6, 2009 Well, I think we have the final diagnosis!!........ I rang my dealer back to understand where he got the solid flywheel theory from and further question him. Basically, Ford's replacement part list has a solid disc, so methinks they know they're not that good! He did confirm though that my noise was like no other DMF failure they've had and have confirmed it is the gearbox :blink: I might as well change the clutch and DMF as well to save further expense as the car's done 78k. Final costs I've got are; GSF Clutch Quote
Animal169 Posted March 18, 2009 Author Report Posted March 18, 2009 Hi all, Just to let you all know the final outcome; The prices were almost as above, the only changes being with GSF, they came up trumps in that they were able to supply a clutch kit that included the DMF for under Quote
c ackerman Posted October 9, 2009 Report Posted October 9, 2009 Well, I think we have the final diagnosis!!........ I rang my dealer back to understand where he got the solid flywheel theory from and further question him. Basically, Ford's replacement part list has a solid disc, so methinks they know they're not that good! He did confirm though that my noise was like no other DMF failure they've had and have confirmed it is the gearbox :D I might as well change the clutch and DMF as well to save further expense as the car's done 78k. Final costs I've got are; GSF Clutch Quote
c ackerman Posted October 9, 2009 Report Posted October 9, 2009 Well, I think we have the final diagnosis!!........ I rang my dealer back to understand where he got the solid flywheel theory from and further question him. Basically, Ford's replacement part list has a solid disc, so methinks they know they're not that good! He did confirm though that my noise was like no other DMF failure they've had and have confirmed it is the gearbox :D I might as well change the clutch and DMF as well to save further expense as the car's done 78k. Final costs I've got are; GSF Clutch Quote
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