(Edit: This was for my older 2004 6.0 truck. My new 6.4 2008, no problems)
Short Version:
MY TRANS CLUNKS from 2nd to 3rd gear (every time). It's getting worse. Ford says it's normal. 34k now...what to do?
Long Detailed Version:
My trans has recently (10k miles ago, or 6 months) started clunking when shifting from 2nd to 3rd gear.
The clunk has gotten steadily worse over this time. I'm at 34,000 miles now and I'm really not getting anywhere in getting this resolved.
I've had it in the shop three times for this and two times, they did something about it.
First was at the local Ford dealer and they re-flashed it. Well, obviously it didn't cure it, but...what the heck..they tried.
So, I bring it back in (it's getting louder). They say "oh yeah, we can hear that". They tear down the transmission and put about $900 worth of parts into it (plus labor). The truck is in the shop about 5 working days. I'm called to pick it up and drive it around the block just to verify. Well, CLUNK!
Anyway, I left it. They called me the next day to say "cannot verify customer complaint". So, I leave work and drive over there. I drive around the block again and bring it back. CLUNK on every 2-3 shift. They call out the trans guy and he's pissed. He can't even look me in the eye. He says "it's not the blankity-blank trans". I say "let's go for a ride.
I drive and he's the passenger. Well, sure as blank, he hears and feels it in the floorboard.
I do it three more times for him (normal driving, not fast). He's stumped. He says they're going to have to call out the Ford engineer. I leave it again.
4 days later, they call and say "that's normal" and site some bulletin from Ford that they have. I've never seen a copy. I asked what they can do and they tell me "nothing".
So...a couple days later, I take it into Sunrise Ford. I figure that since I bought the truck there, maybe they can fix it.
I leave it and pay for a rental car (Chevy Aveo, cheap and small). The next day, I get "the call". I'm told that there is a TSB from Ford that says that some 03/early 04 diesels with the torqshift trans exhibit a clunk from 2nd to 3rd gear. It further states that this is caused by some sort of excessive clearance in the trans. (must be that "normal" excessive clearance....what's normal about "EXCESSIVE" clearance?)
Now, what to do.
Option 1: Get a new truck (this is costly and my truck is great except the trans...especially after the new steering gear, glow plug relay (controller?), rear differental (complete replacement) and the oil leaks were fixed (I think they're fixed)
Option 2: Scream bloody murder. In 2k, I own this trans. I don't have high hopes that it's "normal". It's "normal" is what they are telling all of us with the problems the can't fix.
I don't want a new truck, I just want a trans that doesn't clunk. I don't like to feel it in the floorboard and I hate when people ask me "what was that? Did you run over something?". I think Ford should step up and do 1 of the following:
1. Rebuild my trans
2. Install a new trans
3. Warranty my trans the same as the engine.
If I got 5 years or 100,000 miles (whichever came first) out of my trans, I wouldn't complain.
A trans rebuild is going to cost me about $2500.
An extended warranty is going to cost me about $2500.
I don't think I should have to do either.
I realize that the trans warranty is only 3/36, but....I'm identifying a problem that exists NOW and is steadily getting worse.
What to do???
Any advice is appreciated.
-T
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