Manual Gearbox experts?

[nhudson1]

I'm not sure if its an issue or just a significant nuisance.  The car in question is a 2013 Focus 1.6 TDCI manual with 60k miles.

The gearbox has no issues finding gears, up, down or skipping from say 3rd to 5th and back ect.  When sat idle, engine running or off, there is no issue at all.

The main issue is only present when the car is moving or basically just coasting, but it has to be in motion and occurs when the clutch is not engaged \ peddle depressed.

When shifting from 1st to 2nd or 2nd to 1st only, there is a significant crunch noise, like metal on metal, but not issues of getting into gear. All other gears are fine. 

There is also a louder than expected heavy clunk when engaging / disengaging the clutch when shifting from 1st to 2nd and 2nd to 1st, these gear changes only and the shifts have to have been made when the car has moved, the fault is not present after the car has been stationary or is at idle. 

I'm not sure if the problem is getting worse or how long its been doing it, as its my wife's car and not my daily driver. 

I was wondering if anyone had ever had an example similar to this at all, Focus or other type and what the fault was or could be?

[Bdevo3]

Possibly a worn gearbox or engine mount. Vibration up the clutch pedal would indicate a problem with the flywheel clutch assembly. Grinding or notchy would point towards worn clutch plate or synchro.

[nhudson1]

Thank you for the reply, there's no noticeable vibration in the pedal.

I'm just so confused that it only happens when the car is moving or has just stopped, but then can't be replicated again until the car moves off again.

[Turbojuice]

Could it be that your clutch is dragging a little? Might just need bleeding.

[227bhp]

nhudson1 said:

The main issue is only present when the car is moving or basically just coasting, but it has to be in motion and occurs when the clutch is not engaged \ pedal depressed.

I don't know what you're doing changing gear with the clutch not engaged?

Otherwise sounds like 1st/2nd syncromesh worn.

[996TT02]

Sounds like the clutch is not fully disengaging - is the bite point low down on the pedal travel i.e. does the car start to move with the pedal barely off the floor?

Hence the knocking.

[E-bmw]

227bhp said:

Otherwise sounds like 1st/2nd syncromesh worn.

Unfortunately my vote goes here also.

[nhudson1]

227bhp said:

I don't know what you're doing changing gear with the clutch not engaged?

Otherwise sounds like 1st/2nd syncromesh worn.

Sorry, I meant when you disengage the clutch to change gear, select the gear and then release the peddle. The noise is between the change and not on bringing the clutch up or down.

To try and replicate the noise, if i coast / roll slowly and move between 1st and 2nd, then the clunk noise is there.

[nhudson1]

996TT02 said:

Sounds like the clutch is not fully disengaging - is the bite point low down on the pedal travel i.e. does the car start to move with the pedal barely off the floor?

Hence the knocking.

No, the clutch is pretty good, not a low biting point.

[nhudson1]

Tonight I had the car, and its quite cold, maybe 3'c. There was not the slightest knock at all changing gears. I wonder, could it be a oil problem or heat issue?

I appreciate all the replies and advice!

[GVK]

E-bmw said:

227bhp said:

Otherwise sounds like 1st/2nd syncromesh worn.

Unfortunately my vote goes here also.

Sadly this!

[Turbojuice]

Just a thought. Have you tried double declutching when changing gear?

[Bdevo3]

Turbojuice said:

Just a thought. Have you tried double declutching when changing gear?

This it could be a weak hydraulic release bearing

[Steve_D]

If these symptoms are temperature sensitive then perhaps and oil change would be a good move before thoughts of removing/replacing the 'box.

Steve

[DuraAce]

Your synchro could well be in its way out.
As that's a big job to fix I would check the oil level in the box first, if level is ok then I would change the oil anyways... Very easy to do.

[Sardonicus]

If it temp dependent it can also be knackered moisture laden brake fluid (old age) get the clutch fluid renewed its a cheap possible fix (I know of no garage that does this at service) I do as part of a brake fluid service always for this very reason next time the car shows this behavior stop and select reverse if it crunches with the clutch disengaged it will be what I mentioned or a faulty hanging/dragging clutch driven/friction plate

Edited by Sardonicus on Wednesday 3rd January 15:38