Manual transmission scraping noise / grinding sound

[I3lackRose]

Even if “there’s a magnet you’re fine” was a good enough excuse to just continue adding more metal shavings into a brand new gearbox when a known issue exists that Ford hasn’t fixed, you’re forgetting one key issue. Synchros are typically brass. Brass is not magnetic.

I thought they were brass but I guess the parts in the picture don't look brass to me is what I'm saying. Looks steel and the fragments on the one photo look like steel shavings.

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[SPITmadFIRE]

I thought they were brass but I guess the parts in the picture don't look brass to me is what I'm saying. Looks steel and the fragments on the one photo look like steel shavings.

Those photos show the damage the grinding synchros do to the gears themselves, presumably from friction welds

 

[Bmadda]

So I had a little spare time at the end of the day and decided to try changing my fluid. 1st off I wanted to save what I got out and measure how much. I recovered almost exactly 2.5 qt. Drained it into a clean antifreeze jug (w/top cut off), then after settling i poured it back in the quart jugs. No metal flake, no visible metal of any kind in my jug. Fluid was a little dark from heat, but otherwise perfect.

I have read posts that say if the vehicle is pointed uphill, the noise stops...causing some of us to think possibly there is a lack of lube to the rear of the case causing the noise. I'm not sure i buy that theory, but I noticed the fill hole is nearly all the way to the rear of the trans, so I figured if I filled it w/the rear end jacked up, I might be able to get a little more in it, and yes, I was able to pump 3 quarts before any trickled out. I then did my best to force feed a 4th quart, and quickly install the plug before it all leaked back out. I'm not saying this is a solution, and if it pukes fluid out of the vent, thats on me. But its something I want to try. Will post my results in a few days!

 

[I3lackRose]

So I had a little spare time at the end of the day and decided to try changing my fluid. 1st off I wanted to save what I got out and measure how much. I recovered almost exactly 2.5 qt. Drained it into a clean antifreeze jug (w/top cut off), then after settling i poured it back in the quart jugs. No metal flake, no visible metal of any kind in my jug. Fluid was a little dark from heat, but otherwise perfect.

I have read posts that say if the vehicle is pointed uphill, the noise stops...causing some of us to think possibly there is a lack of lube to the rear of the case causing the noise. I'm not sure i buy that theory, but I noticed the fill hole is nearly all the way to the rear of the trans, so I figured if I filled it w/the rear end jacked up, I might be able to get a little more in it, and yes, I was able to pump 3 quarts before any trickled out. I then did my best to force feed a 4th quart, and quickly install the plug before it all leaked back out. I'm not saying this is a solution, and if it pukes fluid out of the vent, thats on me. But its something I want to try. Will post my results in a few days!

Kinda looks like flakes in picture but hard to say? You sure no flakes? Won't the transmission fluid need some room to expand from heat operation?

 

[SPITmadFIRE]

@Bmadda that’s some good news! How many miles do you have on the truck and how long has your grinding been occurring if you don’t mind me asking?

 

[Bmadda]

@Bmadda that’s some good news! How many miles do you have on the truck and how long has your grinding been occurring if you don’t mind me asking?

4150 mi, and I have been following this topic, but have not heard the noise until last night (at least noticeably...since you guys have been reporting this I have been listening, but couldn't hear anything I considered abnormal...2.3 is a little noisy when cold normally). I figure if it IS a lube issue, best to figure that out right away. Fingers crossed!

 

[SPITmadFIRE]

4150 mi, and I have been following this topic, but have not heard the noise until last night (at least noticeably...since you guys have been reporting this I have been listening, but couldn't hear anything I considered abnormal...2.3 is a little noisy when cold normally). I figure if it IS a lube issue, best to figure that out right away. Fingers crossed!

Mine sounds like there's a garden gnome hiding under my truck sharpening two stones together, so if you're not hearing it consistently it's probably not occurring

 

[Bmadda]

Mine sounds like there's a garden gnome hiding under my truck sharpening two stones together, so if you're not hearing it consistently it's probably not occurring

I hear it consistently, but only when cold at this point, and when it does it it is quite loud. actually louder outside the vehicle from a few feet away! Sounds more like somebody left a pocket full of change in the dryer to me...course I have limited experience w/garden gnomes!

 

[Stlrfan152]

Dropped mine off at the dealer today, they are keeping it till parts arrive. They said they are doing the tsb and need to replace some of the gears. One part is backordered. I guess ill have to enjoy my ford edge loaner for a few weeks.

 

[Bmadda]

Kinda looks like flakes in picture but hard to say? You sure no flakes? Won't the transmission fluid need some room to expand from heat operation?

If there was metal in that jug, that light would make it look like a disco ball in there. Ya the fluid might puke out of the vent from my slight overfill, but easy enough to readjust it to the sight plug if I have that problem. this way I am 100% sure it's full. Wouldn't be the 1st time that the book was wrong!

 

[Unclebutter]

Thanks for EVERYONE’s entry’s here! I took my ‘22 Badlands 2.3 7MT in today for what sounds to be the same thing. They are keeping it overnight. They needed more time to determine where the sound originated from. I can’t definitively say it’s the transmission. It sounds like a rock in the calipers sometimes or a grinding in the front left like a transfer case or CV joint. I first noticed it 5 months ago. It was in 4A. I generally drive in 2WD. I thought it might be a 4WD sound but did not go away when shifting to 2WD. I’m hoping for the best. We absolutely love our Bronco!

*UPDATE*

I got a call from the head of Techs at my Ford dealership telling me that Ford sent them a TSB for 5th and 6th synchro gear rings on the 7MT. The TSB describes all the symptoms that we all have been having: grinding noise on first and second gear when driving, grinding noise while the clutch is engage (50 degrees or lower temp) and slightly going away when warm, and the noise going away when putting the shifter on sixth gear without pressing the Clutch in. She’s going to order the parts and let me know when they’re there so I can bring my bronco in and get it all fixed up. I was hoping I could hear this from them, she told me the smartest thing was to wait for a TSB instead of doing anything mayor. Will keep you guys updated!

 

[91tii]

I'm not saying this is a solution, and if it pukes fluid out of the vent, thats on me. But its something I want to try. Will post my results in a few days!

I'm just starting to notice a faint knocking/grinding sound on cold starts in my '22 badlands 7mt with about 3k miles. Very interested to hear the results of a fluid overfill. To me it does seem possible that it is a result of poor lubrication on those synchros. Thanks for trying it out, keep us posted!

 

[Unclebutter]

Got my rig back today after an over night at the dealership. TSB for MT7 was found and parts are ordered. Not sure when they will come in.
FORD , are you listening? How about extending our vehicle warranties to 100,000 miles on these Broncos? That would go a long way to restoring our faith. I love this vehicle but am very concerned about repairs this extensive at such low mileage. I first became aware of the sound around 5000 miles.

 

[Dingbat]

Dropped mine off Monday. They looked at it yesterday and agreed symptoms lined up with the TSB. Parts are on order and not expected in until mid February. They gave my Bronco back to me and said Ford said it was fine to drive in the mean time. Think I'm going to leave it parked though just to be safe.

 

[I3lackRose]

Thanks for EVERYONE’s entry’s here! I took my ‘22 Badlands 2.3 7MT in today for what sounds to be the same thing. They are keeping it overnight. They needed more time to determine where the sound originated from. I can’t definitively say it’s the transmission. It sounds like a rock in the calipers sometimes or a grinding in the front left like a transfer case or CV joint. I first noticed it 5 months ago. It was in 4A. I generally drive in 2WD. I thought it might be a 4WD sound but did not go away when shifting to 2WD. I’m hoping for the best. We absolutely love our Bronco!

Idk your issue described sound different? The sound happens during driving but it's most noticable on Cold start just warming up idling out of gear clutch out when it's 50* or under

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