[Burnin21]

Hey Guys,

I have a weird rattle i just noticed at idle on my 04' ZX5. However this rattle goes away when I push the clutch in. Any ideas?

Matt

[DILATED]

Hey Matt,

If you have your foot off the clutch and the car in neutral, it's the throw out bearing in the clutch that is making that sound. Sounds like a tractor. Pretty much everybody has this common complaint. Nothing to worry about.

Vito :)

[_JC_]

i got it tooo
and have had it for a longgg time

[ZX3 in progress]

YUP I've had the same problem with mine since I got it almost 2 years ago.

[ZX3TUNR]

Got it here to. No big worries. I find it starts making the sound the worse after driving the car hard.

A local guy here went through a lot of crap from Ford getting it fixed...

[Flofocus]

Really....I have it to, but I always thought it was a lose exhaust connection or something. <_<

[ANTHONYD]

It's called gear roll over noise.

No big deal.

[redsvtfocus]

me too.... since a couple of ppl told me that...I dont worry about it.. ;)

[CanadaSVT]

There is a TSB out on this problem with the SVT's. Anyone have the #? I can get it tomorrow. Everyone I know with a SVT with this problem has had it fixed under warranty, except for 1 who was just outside the warranty period (103,000km).

T.S.B. 04-12-2

"FORD: 2002-2004 FOCUS


ISSUE:
Some 2002-2004 SVT Focus vehicles may exhibit a clunking or rattling noise in the transaxle, mainly at idle in neutral. The noise can typically be reduced by slightly depressing the clutch pedal.

ACTION:
The noise may be caused by a dual mass flywheel issue, worn splines on the clutch disk, or by a transaxle misalignment issue. To service, refer to the following Service Procedure.

SERVICE PROCEDURE
Check transaxle fluid level. If low, fill to correct level and retest for noise. If noise is still present proceed to Step 2.
Remove the transaxle. Refer to the appropriate model year Workshop Manual Section 308-03C; Manual Transaxle/Transmission - MT285; Removal.
Inspect the transaxle slave cylinder assembly.
Inspect for leaks.
Inspect the clutch slave cylinder and bearing as follows:
Rotate the outer race while applying pressure. Inspect for roughness.
Inspect for any surface scoring or burrs that may impede the sliding motion of the clutch release hub and bearing. Any scoring or burrs should be polished off with a fine grade of emery paper.
Replace the slave cylinder as necessary. Refer to the appropriate model year Workshop Manual Section 308-02B: Clutch Controls - MT285/MTX75 Transaxle; Clutch Slave Cylinder.
Inspect the transaxle input shaft.
Inspect input shaft for damage, spline wear, burrs or rough surfaces. Any scoring or burrs should be polished off with a fine grade of emery paper.
Replace transaxle as necessary.
Remove the clutch pressure plate and clutch disk. Refer to the appropriate model year Workshop Manual Section 308-01C; Clutch - MT285 Transaxle; Removal and Installation; Clutch Disk and Pressure Plate.
NOTE: REPLACE THE CLUTCH DISK DUE TO POSSIBLE HUB SPLINE WEAR OR FRICTION MATERIAL WEAR.



Inspect the clutch pressure plate.
Check the clutch pressure plate surface for scoring, cracks or discoloration. Minor scratches or discoloration should be removed with a fine emery cloth.
Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments and spring ends that are higher or lower than the rest.
Replace the pressure plate as required.
Inspect the dual mass flywheel surface with flywheel installed on engine for scoring, cracks or discoloration.
Inspect the dual mass flywheel with flywheel installed on engine for proper internal spring operation as follows:
Install flywheel holding tool 303-103 (T74P-6375-A).
Using a long screwdriver or bar firmly rotate the secondary mass clockwise. The secondary mass should begin to engage the internal spring past the free play movement of 19 mm maximum (.750"). The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure (Figure 1). If the secondary mass does not rotate, replace the dual mass flywheel.



Using a long screwdriver or bar firmly rotate the secondary mass counter clockwise. The secondary mass should begin to engage the internal spring past the free play movement of 19 mm maximum (.750"). The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure (Figure 2). If the secondary mass does not rotate, replace the dual mass flywheel.



Using a long screwdriver or bar rotate the flywheel back and forth until the friction control plate is centered between the secondary mass notches (Figure 3). Inspect the plate for damage or melting. If damaged, replace the dual mass flywheel.



Inspect the dual mass flywheel with flywheel installed on engine for proper secondary mass rotational free play as follows:
Verify that the friction control plate is centered between the secondary mass notches. The rotational freeplay check can not be performed if the plate is off center or damaged (Figure 3).
Place a reference mark on the secondary mass of the flywheel (Figure 4).



Rotate the secondary mass of the flywheel clockwise using light hand pressure until it stops. Use only sufficient force to take up the freeplay in the secondary mass.
Place a reference mark on the primary mass of the flywheel aligned with the mark on the secondary mass (Figure 5).


Rotate the secondary mass of the flywheel counter clockwise using light hand pressure until it stops. Use only sufficient force to take up the freeplay in the secondary mass.
Place a second reference mark on the primary mass of the flywheel aligned with the mark on the secondary mass (Figure 6).


Measure the distance between the two marks on the primary mass of the flywheel. The rotational free play spec is 19 mm maximum (.750") (Figure 7).



Inspect the dual mass flywheel on a bench.
Remove the dual mass flywheel.
Place the dual mass flywheel on a flat level surface. Blocks may have to be placed under the flywheel to prevent movement.
Inspect the dual mass flywheel for hub bushing wear as follows:
Place a dial indicator onto the secondary mass of the flywheel.
Using light hand pressure press downward onto the opposite side of the secondary mass until it stops. Use only sufficient force to take up the freeplay in the secondary mass. The secondary mass should not move more than 1.5 mm (.060") vertically (Figure 8).
Repeat Substep 10-c-2 in three places around the flywheel.



NOTE: AXIAL MOVEMENT OF THE SECONDARY MASS IS NORMAL AND THE FLYWHEEL SHOULD NOT BE REPLACED BASED ON THIS MOVEMENT (FIGURE 9).



Replace the dual mass flywheel as required.
Inspect the rear face of the engine block.
Ensure that the two required engine dowel pins are installed and are not damaged. If the dowel pins are missing or damaged replace as required.
Inspect the corresponding dowel pinholes on the transmission. Ensure the holes are not elongated or damaged.
Inspect the upper and lower plates for damage or warping. Replace as needed.
Inspect the crankshaft flange and flywheel, for residual thread locking compound or rust. Clean as necessary (Figure 10).



Install dual mass flywheel.
NOTE: INSTALL NEW FLYWHEEL RETAINING BOLTS.



Tighten the bolts in sequence, to 112 N-m (83 lb-ft) ( Figure 11).



Install the pressure plate and disc. Refer to the appropriate model year Workshop Manual Section 308-01C; Clutch - MT285 Transaxle; Removal and Installation; Clutch Disk and Pressure Plate.
NOTE: TIGHTEN THE PRESSURE PLATE BOLTS TWO TURNS AT A TIME IN SEQUENCE TO 29 N-m (21 LB-FT). REFER TO (FIGURE 12).







NOTE: ENSURE THE DISC IS PROPERLY INSTALLED WITH "TRANS SIDE" LABEL FACING THE PRESSURE PLATE.



NOTE: INSTALL NEW CLUTCH PRESSURE PLATE RETAINING BOLTS.



Install transmission. Refer to the appropriate model year Workshop Manual Section 308-03C; Manual Transaxle/Transmission - MT285; Installation.
NOTE: THE TRANSMISSION BOLTS HAVE FOUR UNIQUE LENGTHS AND WILL ALL FIT INTO ANY OF THE THROUGH HOLES OF THE TRANSMISSION TO ENGINE BLOCK. IT IS CRITICAL THAT THE PROPER LENGTH BOLT IS INSTALLED INTO ITS PROPER MATING HOLE (FIGURE 13).





NOTE: TORQUE THE TRANSMISSION BOLTS IN SEQUENCE TO 48 N-m (35 LB-FT) TO ENSURE PROPER TRANSAXLE TO ENGINE BLOCK ALIGNMENT (FIGURE 14). ".

[Burnin21]

Well at least the sound is no big deal.....I was worried for a second thinking I may be running the car to hard, and that things were starting to break on me :huh:
Thanks for the help again :)

Matt