Dealers refusing to acklnowledge issue

skematicgnu84

Hi all, this is my second thread here and unfortunately things are getting no better with me and my 'new' 09 plate Focus.

I reported last week that the car has developed a rattle which sounds like it's coming from the gearbox area. This happens when the car is at idle and outta gear, especially stood outside the car on the passenger side, it sounds like somethings rattling itself to bits!

Anyway, the garage have just rang to say the technician has been out for a drive and the only noise he can here is the engine. I explained that i agree, when driving the noise of a 4 year old Diesel out weighs the rattle and asked them to try and diagnose with the car out of gear and stood still.. as if they were at the lights or a junction.

As they refuse to accept theres an issue and my initial 3 months warranty fast running out, what can i do? This is the second time the car has been back to have repairs, but not connected to what it's in for now.

Thanks

Inner_Zone

Sounds like (pardon the pun) the DMF is rattling (assuming it has one). The symptoms were exaclty the same on my Vectra diesel. While the DMF might be covered under warranty, I doubt the clutch will be and will probably need changing as well.

skematicgnu84

Which is exactly my thoughts Inner Zone! I'm now having to get out of work early, drive 65 miles home to start the car and point out a rattle to a 'technician'!

GolfBravo

Ah yes, the good old DMF (dual mass flywheel). Sometimes the noise will go away when you press the clutch pedal, sometimes it will get noisier.

A faulty DMF will always give you plenty of warning signs (i.e.. rattling noise), but will eventually disintegrate. You're looking at the DMF and clutch kit replacement cost.

Find an independent garage (DMF under £250, clutch kit under £150 & 4-6 hours work) - a franchised Ford garage would charge £1K+.

skematicgnu84

With the car still under warranty GolfBravo i'm hoping i don't have to part with any ££

skematicgnu84

Well i've been and at first they passed it off as 'just a neutral gearbox noise'. After running the car they admitted that there is something and think its the release bearing, but replacing it might not cure the issue as 'sometimes they just rattle'!

GolfBravo

skematicgnu84 wrote: »

'sometimes they just rattle'!

Release bearings don't rattle, it's most likely the clutch springs.

Faulty release bearing would make a grinding noise. Faulty DMF could also make a grinding noise.

Unfortunately there is no 100% reliable method to test the DMF and release bearing without dismantling.

The only thing that I can think of is to briefly put the bearing and DMF under stress and then listen to any noises: level road, engine on, clutch pedal in, select 1st gear (maybe even 2nd), no throttle, and then really slowly start releasing the clutch pedal, let the car move. The DMF will be under maximum stress, literally working its nuts off, so if anything is wrong you will definitely hear it.

Another method is to accelerate hard in 4th or 5th gear from around 1200rpm and see if the clutch slips at max torque revs.

Also noisy rattle (imagine sort of metal springs in a washing machine) when turning engine off would indicate a faulty DMF.

mattyprice4004

GolfBravo wrote: »

Release bearings don't rattle, it's most likely the clutch springs.

Faulty release bearing would make a grinding noise. Faulty DMF could also make a grinding noise.

Unfortunately there is no 100% reliable method to test the DMF and release bearing without dismantling.

The only thing that I can think of is to briefly put the bearing and DMF under stress and then listen to any noises: level road, engine on, clutch pedal in, select 1st gear (maybe even 2nd), no throttle, and then really slowly start releasing the clutch pedal, let the car move. The DMF will be under maximum stress, literally working its nuts off, so if anything is wrong you will definitely hear it.

Another method is to accelerate hard in 4th or 5th gear from around 1200rpm and see if the clutch slips at max torque revs.

Also noisy rattle (imagine sort of metal springs in a washing machine) when turning engine off would indicate a faulty DMF.

Release bearings can indeed, and do, just rattle. They're going to fail relatively soon when they start to rattle.

Usually it's the ball bearings or the bearing race wearing down, allowing one half of the bearing to 'dance' against the other, either that or the mounting holding the two halves together has developed play.

skematicgnu84

Well today's update is that there's no problem. The garage have rang to say that the 'Service Manager has looked at the vehicle and the rattling noise is normal for the gearbox and no repairs are necessary'..

Hmm i say, 'well what if something fails after the warranty runs out and i already reported i had an issue with it beforehand?'.. Unfortunately i can't answer that as i don't get involved, but i'll get the Service Manager to ring you back!

facade

Just to rain on your parade a bit, most likely the DMF would not be covered by a warranty as they are a consumable "wear & tear" item.

skematicgnu84

That did cross my mind facade, but as i only had the car three weeks before the fault was reported i'm hoping it's up to them to fix!

Here's a list of events to date -

·17th June - Collected car from Evans Halshaw Middlesbrough (paint repair needed on front bumper, original repair was damaged when valeters cleaned car with 'a diesel powered jetwash'
·28th June - Knocking and sensitive throttle reported to Evans Halshaw Service department
·1st July – Called to update the dealers service department re: loss of throttle
·1st July – Dropped car off – fault last happened this morning on A1(M)
·2nd July - Call to dealers they saying no fault found and no repair will be made - spring replaced in brakes – I made them aware of warn drop link and that this needed replacing
·2nd July – I dispute ‘no fault found’ and email is sent to Pendragon
·3rd July - Called dealers to advise I’m working away and not available until Friday. They advised further part on order (unsure what this is)
·5th July - Car collected - spring replaced on rear brake callipers along with potentiometer - drop links not replaced
·11th July - Call to dealers to report knocking from rear was still present and that rattling noise had also appeared from gearbox area (also paint repair was needed as agreed upon delivery)
·13th July - Car dropped off
·15th July - Call from garage to say drop links were on order and no issue with gearbox, only noise present is engine noise
·15th July - Visited garage and was told that it 'may be the release bearing although sometimes these 'just rattle' or possibly DMF' - await phone call tomorrow after technician speaks to service manager
·16th July – Voicemail left to advise the car is ready for collection. Spoke to dealership who advised service manager has seen car and rattle is ‘normal’. Replied to Dealer Principle email regarding initial throttle complaint advising of issues and asking who would be liable if fault deteriorates after three months warranty expires