Loud Clicking noise MK6 2006 RWD

[transom]

Hi all, I'm at my wits ends with this. It started about 6 months ago and has got progressively worse.

It always happens 1st thing in the morning whilst driving at low speed and changing gears. It is a loud clicking noise coming from gearbox, flywheel area. Once at high speed i.e on the motorway its fine. It will then start again from starting, traveling around at 30 -40 mph. It was initially doing this maybe once or twice a week, it's now a daily thing. I have been to my mechanic, who suggested he change the viscous fan, still the same problem. I then began having trouble starting, put a new starter on. It now will not start sometimes, it will take 3 - 4 attempts. Went to a local specialist in gearboxes, flywheels. They couldn't diagnose it.

I had the solid conversion fitted about 3 years ago as this was recommended, the specialist are now saying they will not fit solid flywheels and have reverted back to dual mass. Could it be a problem with the solid flywheel ? I don't really want to go to the expense of putting a dual mass back on, and this not be the problem !!

Is it worth going to FORD to see if they can diagnose it ?

Any help would be greatly appreciated.

Many thanks.

Tom.

[Spacecat23]

I can't see there being a problem with the solid flywheel, unless its somehow worked itself loose. When you say fails to start is the engine turning over, or is there a high pitched grating sound on the start attempts?

Can failing release bearings tick anyone?

[transom]

Hi, thank you for your reply. Yes its a high pitched grating sound, like when you turn the key when the engine is already running. No, the engine will not start. As my mechanic put a brand new starter in and it continued to do this, he replaced it with yet another brand new one, in case it was a faulty starter.

I found another post on here from about a year ago where a guy had uploaded the noise his van was making, which is very similar to the Clicking noise mine is making. Someone suggested a "noisy injector pump" add some 2 stroke oil to the engine to solve it. I'm not 100% convinced this will cure it ?

viewtopic.php?f=54&t=164748&p=1399379&hilit=clicking+noise#p1399379

[Spacecat23]

If any starter that you put on is doing this I'd suspect the flywheel ring gear. Did your mechanic get a look at that whilst the starter was off? Damage to that would stop the starter pinion engaging, hence the noise of the gears not meshing. How long after the new flywheel was put on did it start doing it? That problem normally starts occurring with a failing dual mass flywheel. Are you sure they put a solid on?

As for the 2 stroke it would do no harm to try it, I'm not convinced it does anything but if it quietens down then you have the culprit for the ticking. 300 mil per full tank is the recommended amount I think.

[Spacecat23]

Try running the engine briefly with the serpentine belt disconnected. See if the ticking stops

[transom]

Hi, the mechanic didn't mention anything, so simple answer is NO, he probably didn't !

It was definitely a solid conversion they put on, this was about 3 years ago.

Do you think its time for a new flywheel ? The van has done about 50,000 miles since the solid conversion.

Many thanks,

Tom.

[transom]

Try running the engine briefly with the serpentine belt disconnected. See if the ticking stops

My mechanic has done that to eliminate any of the tensioners, wheel pulleys e.t.c.

Thanks.

[Spacecat23]

Hi Tom

That's a few miles, but with a solid flywheel it should still be good. I'd get the starter took off, examine its housing for any metal particles and have a look to check that the ring gear teeth aren't worn. Also with the starter off see if there's any play laterally on the flywheel by levering against the engine block and gearbox bellhousing. The dmfs (I know you said it's not) have problems engaging the starter when the bearing joining the two flywheel halves starts to wear. If it is a solid flywheel other than it being loose or its teeth being damaged I don't know what would cause that, especially as you've tried different starters.

I'd also give the 2 stroke in the diesel a try to see if that quietens the tick. It could be the clutch release bearing on the way out if the noise is coming from that area

Alan

[transom]

Hi Alan, that's great, at least I have something to go at now. Will try the 2 stoke oil first, if no joy it will be back to the gearbox & flywheel specialist to have a look at what you've suggested.

Much appreciated.

Will let you know how I go on.

Rgds,

Tom.

[Spacecat23]

No problem Tom. Let me know what transpires with it.

Alan

[transom]

Hi Alan & other readers. Finally sorted in December. It was clutch & flywheel.

I had a a solid put on 3 years ago which was recommended at the time. The garage refuse to put solids on now

I had a dual mass & clutch, also a new slave cylinder, its running absolutely sweet now !!

All in for £695, which I thought was reasonable

Many thanks for all the advice given.

Rgds,

Tom.

[andz327]

£695 for a clutch WoW

[Jim Archer]

Bugger me! That's some hourly rate they charge.

Jim

[andz327]

Bugger me! That's some hourly rate they charge.

Jim

Yeah that's exactly what I was thinking