What is life like with your car? Let us know and win £500 in John Lewis vouchers | No thanks
2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - AP16

Hi there,

I have a 2005 Focus 1.6 TDCi Zetec, which has been serviced at the correct intervals etc and really looked after. It's done 93k relatively trouble free miles.

However, just recently I've noticed that 1st and 2nd gear is a quite resistant upon selection - 'crunchy' is the best way I can describe it. After a bit of trial and error this morning, I've worked out that it's only whilst the engine is running that I have the problem. If I turn the engine off, I can run through the gears with no problem at all.

3rd - 5th and reverse select absolutely fine with engine running or not - so the problem lies only with 1st and 2nd whilst the engine is running.

Can anyone help please? Really hoping it's something a bit simpler than having to replace the clutch!! The bite point does seem a tad high, but I can't say it's ever caused an issue before ... (or perhaps I just haven't noticed it.)

Would really appreciate any advice,

Thanks

Edited by AP16 on 05/03/2013 at 09:11

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - AP16

In addition to the above, I've done a bit more research and it sounds like it could be the 'gear linkage' ?

Does that sound right based on the above to anyone?

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - Peter.N.

Could be the linkage or that the clutch is not disengaging properly, although this usually affects reverse more if it doesn't have synchromesh. How far does the clutch pedal come up from the floor before it engages?

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - AP16

Hi Peter,

The pedal does come up quite away from the floor before engaging, atleast 2/3rds if not 3/4trs.

I noticed when driving it this lunch time that even resting my foot on the clutch pedal slightly seems to be engaging the clutch very slightly.

What are your thoughts?

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - Cyd

sounds like a worn clutch.

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - AP16
I did think it may be, however with the 'pull away in 3rd gear' test, it flatly refuses. Stalls every time, whether I give it high revs, or try to tickle it away... It will not pull away in third.

Yes the bite is high, but I've had audis in the past that have done the same and gone on forever.

I suppose at this point I either take it to ford or muck on through and monitor it?
2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - Peter.N.

If the bite is high that's probably not the problem, its if have have to push it right to the floor that it may not disengage properly. It was only that you said it would go into gear without the engine running that made me think it could be the clutch as that is a symptom.

The bite is high on my 406 and C5 and they have done 210k and 188k respectively, if you don't slip the clutch more than necessary they can last for many more 1000s of miles.

Have you checked the oil level?

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - AP16

Hi Peter,

I can't say I have checked the oil - I'm assuming (please for give my lack of mechanical know-how!) you're not referring to engine oil, but something to do with the clutch?

If you could kindly expand a little I'll be sure to take a look at it this evening.

For extra info, 1st and 2nd gear felt a little stiff still even with the engine off this morning. But 3rd - 5th and reverse are all as smooth as anything.

Thanks for your help, really appreciated.

2005 Ford Focus 1.6TDCi Zetec - Focus 1.6 TDCi Stiff 1st and 2nd Gear engine runs - Peter.N.

I am referring to the gearbox oil, something that doesn't get checked very often, is there any sign of an oil leak on the gearbox?

The stiffness with the engine off would point to a gear selection fault, could be inside the box but hopefully to do with the external linkage or cable. If it uses cables which many cars do it could be that it is sticking due to lack of lubrication but some dismantling will be needed to remedy it, or even a new cable.

Peter