4 Speed Gearbox Problems

Blue_XR · 27-10-2010, 11:08 PM

My sister has an LS focus. Anyway we serviced the gearbox as it was due after 40000kms and 3 years and you could feel it in the gear change. The service made a very positive difference in the way it changed gears. Anyway about 6 weeks later the gearbox started playing up. There would be a large vibration when it kicks down from higher gears to the lower. This did not feel normal at all. We took it back to the place that serviced the box and he said that this is not the first box in a focus that has done this. He has seen quite a few of these 4 speeds with similar problems. The problem is with the 3rd and 4th gear apparently, but the box will need to rebuilt. Mind you it is now out of warranty. He even told us to go to Ford first and see if they can do anything.

Apparently this is a fault with this gearbox or at least on the earlier models. We have been told that eventually the gearbox will stop working. We are getting it looked at right now, because a gearbox should not be failing at 40,000kms and it does not get driven hard at all.

Has this happened to anyone else's focus? If so what was done about it.

Velociraptor82 · 28-10-2010, 11:00 AM

Hearing about problems with the LS auto isn't uncommon. There are some on this forum who have traded in their cars because of it.

My auto has now done a little under 80k km and I'm noticing increasing glitches such as a thump going down from 2nd to first. long delays riding the clutch going up to 2nd. There is also a noise like a clutch slip between 2nd and 3rd. I havn't done anything about it yet, besides what is done at the normal Ford service, however I don't plan on doing anything until the transmission gives up the ghost. Then I'll switch it to a manual.

XR5-Boy · 28-10-2010, 11:23 AM

There should be an update for the ECU which rectifies this problem (from what i've heard). Check with your local Ford dealership.

Blue_XR · 28-10-2010, 11:34 AM

Thanks for the replies. The car is currently at Ford so hopefully I will have a response soon.

I'll let you know what it is. I just hope the box doesn't need a rebuild. It costs around $3,000

DZFord · 28-10-2010, 05:12 PM

Blue, I'd contac 20focus05, he services auto boxes and has experience working on the Focus. To quote him, the Focus auto box rarely has any problems, except for a minority which have had solenoid issues.

To me, it is too much of a coincidence that the gearbox has packed up 6 weeks after a service (wrong gearbox oil?).

The most common problem with the Focus auto is the very firm downshift from 2nd -> 1st. This is apparently an ECU problem, not a mechanical problem. In fact, before anyone knew this was an ECU problem, Ford rebuilt my tranmission twice (under warranty), but this never fixed anything.

Blue_XR · 28-10-2010, 05:59 PM

Quote:

Blue, I'd contac 20focus05, he services auto boxes and has experience working on the Focus. To quote him, the Focus auto box rarely has any problems, except for a minority which have had solenoid issues.

To me, it is too much of a coincidence that the gearbox has packed up 6 weeks after a service (wrong gearbox oil?).

The most common problem with the Focus auto is the very firm downshift from 2nd -> 1st. This is apparently an ECU problem, not a mechanical problem. In fact, before anyone knew this was an ECU problem, Ford rebuilt my tranmission twice (under warranty), but this never fixed anything.

We have had the box checked and it has been confirmed that she needs a new gearbox. Now we are waiting on customer service to see what they will do.

The gearbox was serviced at a place that only does gearboxes and they have serviced my dad's car for years without any issues. For example we used to have an EA 4 speed. It was playing up and everywhere else my Dad took it to said it needed to be rebuilt. We took it to this place they serviced it and replaced the solenoid and it was working brilliantly again. So I trust these guys. I find that they are very honest in what they tell us.

I need to find out what customer service does from here then I will take the appropriate action in getting quotes etc.....

The replies have been great, thanks guys. I will let you know what happens from here on.

DZFord · 28-10-2010, 06:27 PM

That's not good news. Did they say what was wrong with the box?

Blue_XR · 28-10-2010, 11:28 PM

i'll ring up and find out tomorrow. The service department didnt tell her much. My sister has been dealing with it for now.

20focus05 · 29-10-2010, 09:10 PM

like to know what bits died, Direct Clutch?
I have mostly seen mazda boxes because they use alloy in some parts and the ford box uses steel, mainly in the snout for the direct clutch.
gasket can blow out in the valve body and the band servo can play up(2nd and 4th)
Solonoids can die giving funny shifts cause they are not just normal on/off these ones can gradually open, even though there is 2 on/off ones.
so how many Km's?? 40 odd, now that does not seem right 80-90 maybe even the Mazda boxs made it to that.
If these guys are members of Automatic Transmission Rebuilders Australasia (ATRA)
then you should be getting the right infomation. google ATRA and there is a member list.
I used to be the one to play with these FN4AEL's(Mazda)/4F27E(Ford)
I dont work for the auto trans place anymore.

Blue_XR · 31-10-2010, 03:41 PM

Thanks for that info 20focus05. The place that serviced the gearbox was part of the ATRA. Thanks for that.

Anyway have had some more news now. Ford have not told my sister what exactly might be wrong with it. Customer service have now said that the box has to be pulled apart to see if it is a manufacturer fault. The box being pulled apart is gonna cost a bit but if it is a manuafactuer fault then the cost will be covered by Ford. I would like to know what they were doing with the car for 2 days. So now we have to rebook it.

I have chatted to my sister again to try and get her to remember what the transmittion specailist said to her. She has told me the problem is in the 1st and 2nd gear. That is what has been said to her.

So now we have to take a risk get Ford to pull it apart and hope it is a manufactuer fault. The car has done 47,000km now.

Blue_XR · 18-11-2010, 10:38 PM

Ok, i have some more information now.

Well the gearbox needs to be rebuilt. There is excessive wear on the end cover housing causing grooving on the direct reverse drum sealing ring surfaces. This is what my sister wrote down.

Anyway Ford are covering the bulk of the cost and the gearbox will be sent out to a transmission specialist to be fixed.

20focus05 · 19-11-2010, 10:17 PM

Well there you go we only used to see this on the Mazda boxes because the end cover was made of alloy while the ford box used steel.
As an upgrade when we built a Mazda box we used the steel Ford item.
Had to have been a faulty end cover to wear so soon.
Another funny thing the main customers with the Mazdas where old ladies who gently drove about. Go figure!! and all at about 80000km

Good to see its getting fixed and cover by Ford.

Blue_XR · 23-11-2010, 01:10 PM

Just to let you know. We will be getting a 12 month warranty on the new gearbox. Hopefully this doesn't happen again