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Old 08-27-2012, 11:16 AM   #1
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Going in for service

I'm gonna drop off my ride at the dealer this afternoon for some warranty service. I have a popping noise when I turn to the left. It sorta pops a couple of times like its loose somewhere. This will be under my service warranty.

They will also take a look at what is going on with my tranny/clutch and let me know if this will be covered. I know the TOB is heading south because it recently started to make noise just sitting idling and goes away when you put it the clutch. I'm really hoping that this is related to the metallic noise I hear while driving at ~2000RPM, which goes away when the drivetrain warms up in less than 5 minutes. This noise goes away also when you push in the clutch pedal.
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Old 08-27-2012, 11:22 AM   #2
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Re: Going in for service

TOB wont be covered as its a wear/tear part but regardless it has to be fixed
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Old 08-27-2012, 11:33 AM   #3
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Re: Going in for service

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TOB wont be covered as its a wear/tear part but regardless it has to be fixed
Can you replace the TOB w/o disassembling the clutch? The TOB is the part that goes on the fork, right?
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Old 08-27-2012, 11:56 AM   #4
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Quote:
Originally Posted by Azure

Can you replace the TOB w/o disassembling the clutch? The TOB is the part that goes on the fork, right?
You've got to pull the entire trans to access the tob
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Old 08-27-2012, 12:00 PM   #5
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You've got to pull the entire trans to access the tob
But do I need to unbolt the clutch? I don't have an alignment tool for remounting the clutch or a torque wrench.
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Old 08-27-2012, 12:13 PM   #6
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Re: Going in for service

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But do I need to unbolt the clutch? I don't have an alignment tool for remounting the clutch or a torque wrench.
Actually, if they still sell them or give them away you can pick one up at a local parts store other then Autozone.
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Old 08-27-2012, 12:23 PM   #7
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Actually, if they still sell them or give them away you can pick one up at a local parts store other then Autozone.
I'll have to swing by and check that out. Thanks!

I guess I could rent a torque wrench too. I'd like to leave the clutch along if I can.
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Old 08-27-2012, 12:36 PM   #8
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Re: Going in for service

if you are going as far as to replace the TOB its a GREAT time to consider doing the rest and replacing all the clutch parts etc. You shouldnt have to remove the clutch pressure plate etc to get to the throwout bearing as far as I know though. Use a Ford brand or a Ford Heavy Duty TOB, no other brands.
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Old 08-27-2012, 12:45 PM   #9
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if you are going as far as to replace the TOB its a GREAT time to consider doing the rest and replacing all the clutch parts etc. You shouldnt have to remove the clutch pressure plate etc to get to the throwout bearing as far as I know though. Use a Ford brand or a Ford Heavy Duty TOB, no other brands.
I believe what happened was the aftermarket clutch kit the prev owner had put in, I think they used the TOB from the kit rather than FR TOB.

Thanks
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Old 08-27-2012, 01:49 PM   #10
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Re: Going in for service

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Originally Posted by SpectorV View Post
if you are going as far as to replace the TOB its a GREAT time to consider doing the rest and replacing all the clutch parts etc. You shouldnt have to remove the clutch pressure plate etc to get to the throwout bearing as far as I know though. Use a Ford brand or a Ford Heavy Duty TOB, no other brands.
If I could vote for the best advice on this site I would give this a 100%

---------- Post added at 01:49 PM ---------- Previous post was at 01:48 PM ----------

Quote:
Originally Posted by Azure View Post
I'll have to swing by and check that out. Thanks!

I guess I could rent a torque wrench too. I'd like to leave the clutch along if I can.
Try either orileys or carquest or advance if you have one....if not try the dealership.
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Old 08-29-2012, 09:44 AM   #11
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Well, the dealership suspects its the input shaft bearing pocket that has been making my noise at ~2000RPM. They are dropping the tranny now. If this is indeed the prob, it will be covered under my warranty. Lets hope!

This was the noise that would go away when the drivetrain warmed up. So in the summer, it would stop making noticeable noise by the time you drove out of the neighborhood. Longer during colder months.

They are going to inspect my clutch and supporting cast while they are in to it as well. I know the TOB has recently started to make a little noise when I first startup cause you can hear it go away when I push in the clutch pedal. I will see what else can be replaced.

Does anyone know if the dealerships handle Ford Racing parts?
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Old 08-29-2012, 01:52 PM   #12
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Quote:
Originally Posted by Azure
Well, the dealership suspects its the input shaft bearing pocket that has been making my noise at ~2000RPM. They are dropping the tranny now. If this is indeed the prob, it will be covered under my warranty. Lets hope!

This was the noise that would go away when the drivetrain warmed up. So in the summer, it would stop making noticeable noise by the time you drove out of the neighborhood. Longer during colder months.

They are going to inspect my clutch and supporting cast while they are in to it as well. I know the TOB has recently started to make a little noise when I first startup cause you can hear it go away when I push in the clutch pedal. I will see what else can be replaced.

Does anyone know if the dealerships handle Ford Racing parts?
I know Ray Skillman Ford here in Greenwood IN does. If they are dropping the tranny make sure to get them to replace the TOB too.
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Old 08-29-2012, 02:20 PM   #13
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I know Ray Skillman Ford here in Greenwood IN does. If they are dropping the tranny make sure to get them to replace the TOB too.
I mentioned this to them yesterday that I will be wanting the TOB & pilot bearings replaced before the tranny is buttoned up. She's at Bill Estes Ford. I hope to hear some news soon.
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Old 08-30-2012, 08:47 AM   #14
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They are working on her now. Hope to find out something before Noon. I guess there is a Windstar transmission recall that has then really busy.
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Old 08-30-2012, 04:36 PM   #15
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Re: Going in for service

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They are working on her now. Hope to find out something before Noon. I guess there is a Windstar transmission recall that has then really busy.
Is your tranny a t-45?
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Old 08-30-2012, 04:44 PM   #16
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Is your tranny a t-45?
No, it's a TR-3650. They started putting those in mid 2001.
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Old 08-30-2012, 08:23 PM   #17
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Aw Okie didn't know
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Old 08-31-2012, 12:20 PM   #18
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They got the tranny out this morning and opened it up. They found the input shaft pocket bearings were bad and the input shaft was scored. He said there were some bearings that had excessive wear too. According to the service rep, the input shafts are not available anymore. They will need to put in a new tranny. This is under warranty. So they will need to try to find other options like see if Jasper can rebuild the tranny, etc. I should find out later today, hopefully.
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Old 08-31-2012, 12:25 PM   #19
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Here's some pics the service rep sent me
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Old 08-31-2012, 05:38 PM   #20
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Re: Going in for service

We are still waiting on the warranty company to get the ball rolling. They are looking for cheaper parts, is what the Ford service rep is telling me. The warranty place was closed, for the holiday, when I called them about getting a rental car. I'm kinda screwed until Tuesday I guess. Does anyone have any advice for working with the warranty companies?
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Old 08-31-2012, 05:46 PM   #21
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We are still waiting on the warranty company to get the ball rolling. They are looking for cheaper parts, is what the Ford service rep is telling me. The warranty place was closed, for the holiday, when I called them about getting a rental car. I'm kinda screwed until Tuesday I guess. Does anyone have any advice for working with the warranty companies?
Cheaper parts Hell! Tell them you want Ford parts.
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Old 08-31-2012, 08:30 PM   #22
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Cheaper parts Hell! Tell them you want Ford parts.
I know! I can't believe Ford sells a warranty that doesn't have to use Ford parts!
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Old 08-31-2012, 08:47 PM   #23
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That's jacked up, I've heard of ppl saying this kinda stuff about the ford warranty dept but I just figured they was talkin smack because they screwed somethin up and expected ford to fix it
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Old 08-31-2012, 09:00 PM   #24
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Does anybody know what supporting cast is needed for replacing your clutch? It looks like my tranny work is gonna take weeks so I have time to buy these parts myself and save a little. Here's what I know...

Clutch (I haven't decided what I want yet)
Ford Racing throw out bearing
Ford Racing pilot bearing
Ford clutch cable
?
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Old 08-31-2012, 10:40 PM   #25
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Get a spec stage 2 clutch, I got 1 in my car and I love it.... It stiff but not to bad, I put the bbk aluminum quadrant and adj clutch cable on mine a few weeks ago, cost like $100 at oreilys, it's well worth it
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Old 08-31-2012, 10:50 PM   #26
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Get a spec stage 2 clutch, I got 1 in my car and I love it.... It stiff but not to bad, I put the bbk aluminum quadrant and adj clutch cable on mine a few weeks ago, cost like $100 at oreilys, it's well worth it
Cool! I didn't know oreilly's sold quadrant kits. I do plan on a quadrant and firewall adjuster after my work is done.
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Old 08-31-2012, 11:13 PM   #27
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Yea at advanced you can get a zoom quadrant kit for I think around $90
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Old 09-01-2012, 12:07 AM   #28
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Quote:
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I know! I can't believe Ford sells a warranty that doesn't have to use Ford parts!
Wait is this a Ford ESP plan or a 3rd party warranty company?

Dealers can sell any warranty they want. But if it is an ESP, I don't take screwed lightly.
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Old 09-01-2012, 01:55 PM   #29
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Wait is this a Ford ESP plan or a 3rd party warranty company?

Dealers can sell any warranty they want. But if it is an ESP, I don't take screwed lightly.
It's a third party warranty. "The Mechanic" is the title on the paperwork. It's the platinum version, so it's the highest option. It's for new or used cars, so Ford must use this for their used cars, I assume.
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Old 09-04-2012, 09:46 AM   #30
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Good news! The warranty company approved a Ford tranny replacement! The tranny won't arrive until Monday next week, but I will at least get a rental to drive while I wait.
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Old 09-04-2012, 09:59 AM   #31
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Re: Going in for service

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Good news! The warranty company approved a Ford tranny replacement! The tranny won't arrive until Monday next week, but I will at least get a rental to drive while I wait.
That's fantastic Azure keep on top of them and have them do everything correct. Also, did you ever get a rental car?
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Old 09-04-2012, 10:06 AM   #32
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That's fantastic Azure keep on top of them and have them do everything correct. Also, did you ever get a rental car?
Yup, supposed to pick it up this afternoon.
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Old 09-04-2012, 11:01 AM   #33
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I ordered my Ford Racing pilot and throw out bearings, as well as an Exedy stage 1 clutch kit from American Muscle. I went with the stage 1 to keep it close to the OEM style to try and keep it in line with my warranty. Have you ever priced a stock replacement clutch friction disc and pressure plate? You'll faint, it's just stupid expensive, around $700! : Yay for aftermarket performance parts!
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Old 09-04-2012, 12:33 PM   #34
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Had to let the dealership pick me up an OEM Ford clutch cable for $95. I didn't find one on AM or LMR.
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Old 09-04-2012, 02:25 PM   #35
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Found out the steering rack bushings are going to be covered too.

STILL, after buying the Exedy clutch, FR throw out and pilot bearings, OEM clutch cable, flywheel re-surfacing, $100 warranty deductible and clutch install labor - my bill will be totaling ~$750!

Ouch!
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