Faulty Replacement Gearboxes

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Posts: 3
Joined: Sat May 13, 2017 11:15 am
Make: Ford
Model: Fiesta
Type: ST
Year: 2013

Faulty Replacement Gearboxes

Postby BooSTBoy » Sat May 13, 2017 12:21 pm

Hi All,

Fiesta ST 2013. Bought from dealer (Boksburg) with 25kkm, now on 75kkm. Second gear went at 70kkm. Dealer who services the car (Fury Midrand) replaced gearbox, straight out the workshop it had a very loud "touring car" like gearbox whine in all gears but worse in 4th and 6th. Eventually another gearbox was installed and wait for it......more whining but worse! Between replacement box one and replacement box two, Fury claim there were reports of other incidents of faulty replacement boxes at other dealers but didn't say what models.

Dealership escalated to FordSA but I have also escalated to FordSA who basically have done nothing because when they eventually called me it was clear they didn't even have the background story...the person cheerfully told me that my car was ready for collection....which was odd because I was in my car driving it when they called! The representative then suggested it must go back to dealer for inspection which I said I'm not prepared to do since they have had two cracks at it already. I await further contact from FordSA.

So my question is this, any owners who have had recent gearbox replacements that have had a similar problem?

Other issues I have had with the vehicle,

1) Coolant pipe came off near coolant bottle. Apparently a known issue. Luckily I saw it and stopped immediately. New AA membership to tow and got soaked in a rainstorm trying to fix this "known issue".

2) Left shock mount bearing failed. Metal grinding noise when turning steering wheel.

3) Dealer damaged clip on inner CV boot when replacing first gearbox. Grease splatter everywhere. Dealer claims no damage and replaced clip after driving like that for a few thousand km. How much grease has been lost is anyone guess?!

4) There is a loud clicking noise coming from the centre to right front of car that can be heard if you go to neutral and coast to a stop - Maybe above mentioned CV or gearbox. This appeared between replacement box 1 and 2. Unresolved.

5) Between waiting for the replacement left shock mount bearing and second replacement gearbox I hit a serious pothole which shifted the steering wheel position and clearly caused some damage to the left front. I told the dealer this when it went in for shock mount bearing and gearbox, they told me that I bent the shock but they would "sort it out" in good faith. Driving the car it was immediately clear that something was still wrong, all sorts of noises from front left when pulling off or reversing or accelerating hard. I took it for wheel alignment only to be told that the tie rod is bent. I am happy to make an insurance claim / pay for the damage caused by hitting said pothole but what bugs me is that after working on the front left to replace the shock mount bearing, nothing at all was said to me about what damage there is when there clearly is still damage. This is a safety issue.


Praying car catches fire!

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Posts: 3
Joined: Sat May 13, 2017 11:15 am
Make: Ford
Model: Fiesta
Type: ST
Year: 2013

Re: Faulty Replacement Gearboxes

Postby BooSTBoy » Wed Jun 28, 2017 6:15 pm

Dealer had car for another three weeks. New clutch and flywheel installed on FordSA's instruction. The whining noise remains in 4th and 6th. Gearbox number FOUR has been ordered. HTF can three replacement boxes produce the same result and then they decide they should try number four? Statically impossible!


Damaged CV clip mentioned in original post which dealer said was fixed and wouldn't be a problem.....CV failed. Right side driveshaft replaced or reconed, who knows. Fetch vehicle and there is a new scraping noise at almost full lock from front right.

Back to the dealer.....

Should have bought the GTI.

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Re: Faulty Replacement Gearboxes

Postby Jeff_ZA » Thu Jun 29, 2017 9:49 am

sorry mate, hope they fix soon

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Re: Faulty Replacement Gearboxes

Postby MrMazda » Thu Jun 29, 2017 2:24 pm

BooSTBoy wrote:Dealer had car for another three weeks. New clutch and flywheel installed on FordSA's instruction. The whining noise remains in 4th and 6th. Gearbox number FOUR has been ordered. HTF can three replacement boxes produce the same result and then they decide they should try number four? Statically impossible!


Damaged CV clip mentioned in original post which dealer said was fixed and wouldn't be a problem.....CV failed. Right side driveshaft replaced or reconed, who knows. Fetch vehicle and there is a new scraping noise at almost full lock from front right.

Back to the dealer.....

Should have bought the GTI.


Sounds similar to the gearbox / clutch issues on my previous Mazda 6. Fortunately I had full back up from the DP who never took no for an answer from FMCSA reps. New box + 2 refurbishments on 2nd gear sincro gear + 4 cluthes pd by FMCSA or MP.
Current: 2010 Mazda 6 Active, 2002 Bantam B3 1300, 2010 Sirion 1.3.
Ex:Mazda 323s X 5 1026 000km & 626s X 3 515 000km & B2200 D/c 4X4 345 000km & Meteor GLi 1.6i 120 000km, BMW 528i X2 44 000 km
Mazda 6 2006 Original 222 000km

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Re: Faulty Replacement Gearboxes

Postby FrozenfiST » Fri Jun 30, 2017 11:07 am

That sucks man, hope you get sorted.
Current: Ford Fiesta ST180
Ex:
Hyundai Accent 1.6 SR
Opel Corsa 1.8 GSi
Opel Astra 1.6i

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Joined: Sat May 13, 2017 11:15 am
Make: Ford
Model: Fiesta
Type: ST
Year: 2013

Re: Faulty Replacement Gearboxes

Postby BooSTBoy » Mon Aug 21, 2017 4:30 pm

Update: Gearbox number four went in.....drum roll....still a whine from 4th and 6th. All four replacement gearboxes had a fault from the factory in the differential section, still not sure exactly what since they very hush hush. The problem was finally solved only by by taking the new gearbox to a gearbox specialist who stripped it and fixed it.

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Re: Faulty Replacement Gearboxes

Postby convict 66 » Tue Aug 22, 2017 9:04 am

eish thats not good to hear

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Joined: Mon Dec 05, 2011 11:17 am
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Re: Faulty Replacement Gearboxes

Postby MrMazda » Tue Aug 22, 2017 11:07 am

After 20 k km FMCSA only authorise recon boxes ex Mayfair Gearbox, unless the dealer really press them for a new box, so chances are some of these boxes were ex Mayfair Gearbox in any case, (not one of my favourite suppliers).
Current: 2010 Mazda 6 Active, 2002 Bantam B3 1300, 2010 Sirion 1.3.
Ex:Mazda 323s X 5 1026 000km & 626s X 3 515 000km & B2200 D/c 4X4 345 000km & Meteor GLi 1.6i 120 000km, BMW 528i X2 44 000 km
Mazda 6 2006 Original 222 000km

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