Ford Galaxy tdi

[ltanner]

I am the proud owner of a Ford Galaxy 1.9 tdi, year 03. I have had a problem with the clutch for over a year now.I first reported the fault when the 60,000 mile service was due. But Ford's couldn't find any thing wrong with it. The pedal moves up and down on it's own?? It sometimes gets stuck half way, you have to pull it up with your foot! It gets stuck in first and reverse gears, it burns clutches big time.
In the past nine months Ford's have fitted:
4 clutches, clutch bearings
3 Master Cylinders
3 Slave Cylinders
2 Fly Wheels
And all other pipes and parts connected to the clutch system.
Still the fault remains, worse than ever. Ford's have run out of ideas, as to what the fault is...
Hummmm, didn't Ford design and build it???? They have now suggested it could be the Gearbox.
That's only £4200.00 For a new one. I don't mind, it was reported when the vehicle was still under warranty, it should be covered..... NOT!!!!..... Ford's won't do it because, I have not had it serviced at a Ford garage since the 60,000 mile service, So what!.... I had it serviced by my brother, he works for Range Rover. Why would I have it serviced by them, they couldn't find the fault! Plus because the vehicle has done another 57,000 miles since I reported it? But if they had fixed it when I reported it, a year ago then there wouldn't be an extra 57,000 miles on it, common sense really?????!!!!!! Ford's have now refused to do anymore work on the vehicle, I have tried to discuss the warranty refusal with Ford's customer relations department, not only do they know nothing about cars, they don't make the decisions, No, no, no, the people who decided these stupid excuses are not allowed contact with the outside world, typical really, with no common sense or brains enough to think of a realistic reason,
They can't possibly be human!
What B*****s! excuses for not being able to repair one of their own vehicles.

My advice...

!! DON'T TRUST FORD'S WARRANTY'S !!

[petrolhead]

sounds like there could possibly be some wear on the gearbox input shaft, causing the friction plate not to slide freely when the clutch is released, with the gearbox off run your fingers along the shaft splines and feel for ridges or steps. if your that way minded you can do a bodge-up repair by filing the splines straight again, it works but introduces a little bit of play. that type of wear is usually caused by violent wheelspinning starts.
either that or binding in the pedal linkage or a flexi hose collapsing internally.
from my dealings with ford dealers your probably best off getting your brother to sort it.

[Tel916]

What that man above said...

If you brought a car to me with those issues, I'd immediately investigate any hydraulic clutch system, and my second port of call would be the input shaft/release bearing.

The problem is (and I hate to say it, but I can understand it) the non-Ford servicing. Ford and associated will come up every day, against back-street-servicers who do more harm than good, and I understand that. However, posting your brother's credentials, along with a nice letter to Ford UK HQ, might have decent results. They're surprisingly understanding at the top if you're nice.

Good Luck, sounds like you've been through the mill.

Terry

[ltanner]

Thanks for your comments
Some very technical advice, same sort of advice given by
the independant mechanic we spoke to.
My brother was originally trained by Ford's, he actually became Service Manager until
Mercedes snapped him up, after moving home forced change in employment he now works for
Range Rover, (where he serviced our car).
The reason I didn't get mt bro' to sort it, is because of the warranty issue,
the area manager at Ford's garage said it should be done under warranty.
This is why we left it up to Ford's to repair.

The mention of crank shaft being the fault has cropped up several times,
(although Ford's, VW, and an independant garage have all ruled this out),
it is a bit worrying that I could pay £1000+ for gearbox rebuild to find that it's the
crank shaft after all. More money that I don't want to throw away.
Crank shaft?????? does this mean a new engine, with the mileage the car has done,
I think it's gonna cost more to replace the engine
than the car is actually worth.
I give up, think I'll let the finance company have it back!!!!
They can deal with Ford's!!

[petrolhead]

crankshaft endfloat should be easy enough for them to diagnose, so its not really worth losing any sleep over, and if your brother is doing it replacing the gearbox input shaft (if that is the problem)should cost less than a couple of hundred quid and take a saturday afternoon, provided you supply sufficient amounts of beer? no way it should cost you a grand to get it fixed if you have free or cheap labour and are willing to search for a good deal on parts, no matter whats wrong with it, one of the contributors to car mechanics magazine recently bought a working roadworthy galaxy tdi for £650, and theres bound to be plenty of smashed ones with good engines/gearboxes in breakers. sometime you have to weigh up the cost and hassle of going back and forth to dealers and arguing with people whose job it is to discourage you versus getting your hands dirty and ending up with a result you KNOW is done right and will last. the thing to consider is the condition of the rest of the vehicle, is it one you want to keep for a while, if not, hand it back to the finance company, or look into paying it off then selling it through the auctions, whichever you think will leave you best off.

[Tel916]

Agree with what Petrolhead's said here,

But before you do anything, I'd be tempted to take a flick through the Yellow Pages for a Gearbox specialist; High-mileage or abused versions don't tend to get near the dealer as much, so it may not be a common problem to them, whereas a gearbox specialist may see it every day with that particular box, and be able to offer an informed solution.

Worth a thought, but otherwise. Again. What he said (!)

Edit : If there's endfloat, it should have been picked up during a flywheel change by Ford if they're worth their salt.

Terry