All Manual Owners Read This

blue terra · 03-03-2006, 07:32 PM

G'day this is my first post but i need to pass on what has just happened to my manual xls ute.
found it hard getting gears the other day mainly 2nd. get to one job site and cant get any. win short what has caused this was the nut that sits on the firewall for the clutch has punctured through the firewall meaning the clutch barely worked. it turn what has happened is its burnt the clutch out and needs the dash pulled out and some of the right side in the engine bay to weld a plate in. this is going to be costly

coyote · 03-03-2006, 07:44 PM

Quote:

Originally Posted by blue terra

G'day this is my first post but i need to pass on what has just happened to my manual xls ute.
found it hard getting gears the other day mainly 2nd. get to one job site and cant get any. win short what has caused this was the nut that sits on the firewall for the clutch has punctured through the firewall meaning the clutch barely worked. it turn what has happened is its burnt the clutch out and needs the dash pulled out and some of the right side in the engine bay to weld a plate in. this is going to be costly

was an AU2 XL and the section where the clutch cable went throught the firewall only lasted 45000 km lucky for him it was still under warranty.

Mind you I did 130000 in my AU2 XL manual and never had a problem

The Dok · 03-03-2006, 07:59 PM

Your not an orphan there, this is becoming quite common nowadays. http://www.fordforums.com.au/showthread.php?t=39401
If you use the "search" option, I'm sure you'll find a few more also. Best of luck with it, but surely there must be an easier "fix" than removing the dash unit?? anyone........anyone??

:

S3SR · 03-03-2006, 08:00 PM

i have a similar but i know that there no bolt or cable or firewall or clutch damage... but sometime it wont engage into 2nd and then sometimes when putting it bac into first it thumps pretty loud (can be heard outside the vehicle) also does this sometimes when engaging reverse... a very loud thump and bit of a grind and so on

dont know what the go is maybe need a service or something..

coyote · 03-03-2006, 08:37 PM

I have given up trying to get this fixed, But will have a whinge anyway.
When ideling with the AC on you can hear the gearbbox chruch rattle and roll.
Ford have explained this as Roll over noise and will not do anything about it.
Has done it since about 10000 km and has now completed 120000 and still hanging in there, has not effected the running of the car but is highly frustrating.
Vehicle is a BA 1 XL dedicated gas 5spd

any one else had this issue?????

Cespenar · 03-03-2006, 08:55 PM

This is a common problem with falcons. There is a big variation in their sheet metal. Out of four falcons in my experience, from 96 to 2000, three of them have cracking sheetmetal. mostly in the door holder bits, but obviously in other parts as well. For such a heavy vehicle it should be stronger in the sheet metal than the old dunnydores, but from experience the dunnydore is way superior in this area.

antilooped · 03-03-2006, 09:13 PM

see your private messages

mik · 03-03-2006, 10:40 PM

im just wondering about the firewall thing ,when the car is new everything is lubed from factory including clutch cable,after time and ks elapsed if they bind from lack of lube or being frayed that will put more stress on firewall, also a heavier pressure plate would also, au`s were the first falcon model to have double skin firewall for sound deadening i think ,after seeing these posts i`d be giving a squirt of spray white grease with the tube down the cable at oil change if possible to get at it. my 2 cent worth

black ute · 03-03-2006, 10:47 PM

Same thing happened to my old XG.

We got the old tube section that passes through the firewall, welded it into a heavier piece of steel and bolted it to the firewall. The larger square of steel spreads the load and wont pull through.

Doesn't require dash removal, just somone to lay on the floor with their head under the dash to hold the nuts for you to do them up.

This lasted 100 000 with me, 100 000 with next owner until the car was
T-boned at a stop sign, clutch didn't realy matter after that!

Problem has been around for over 20 years, bout time to do somthing Ford?

XITED_6 · 03-03-2006, 10:54 PM

ive experienced this aswell cost me close to $400 to get the part replaced...luckily didnt fry no clutch. i must say the t5 gear box aint the best has problems selecting gears etc.

EDXR6T · 04-03-2006, 12:36 PM

is this a common problem in just ute's or sedan's to?

**ebxr8240** · 04-03-2006, 12:48 PM

Just put a big plate over it...Then reinforce with this little mod..This is on an E.B but AU are not that different..
http://www.fordforums.com.au/showthread.php?t=36674
Took me no time to make..

Casper · 04-03-2006, 01:05 PM

This issue has become the AU's version of the E series head gasket. Not so much a case of if but when.

svo347 · 04-03-2006, 01:10 PM

Always the usual... its either the firewall or the clutch pedal pivot and they both suck.

LG · 04-03-2006, 01:33 PM

Daim, maybe i should keep my auto... lol

The Dok · 04-03-2006, 01:36 PM

Quote:

Originally Posted by Casper

This issue has become the AU's version of the E series head gasket. Not so much a case of if but when.

True, but the big difference being..........................it's only happening to manual vehicles, :MrT_anim:
thereby affecting a much smaller number of vehicles, of which, I'm happy to add, mine is not one.

:

Casper · 04-03-2006, 01:42 PM

Quote:

Originally Posted by The Dok

True, but the big difference being..........................it's only happening to manual vehicles, :MrT_anim:
thereby affecting a much smaller number of vehicles, of which, I'm happy to add, mine is not one.

:

absoultly.. about 5% of AU's or so I think.

The Dok · 04-03-2006, 01:55 PM

Quote:

Originally Posted by Casper

absoultly.. about 5% of AU's or so I think.

Only @5%, less than I thought then. As the good people at FORD would say, "IT'S WITHIN TOLERENCE"

: