TR-3650 PROGRESS!!!

[smokin91']

1-2 grind problem as many of you probably have experienced plagues my car.

Well finally after 4 times leaving my car over night at Ford, last night was the most recent; I went in to pick up my car after work.

Suprise surprise We cant duplicate the problem. The last few times ive gone in I have spoken to the service manager and he knows who I am. Well actually I wasnt surprised that they tell me "we cant duplicate the problem"

What did surprise me is when the service manager said You've been here enough times there is obviously a problem we need to open the transmission up and look inside, under warranty at no cost to me of course. The service manager asked me if i minded them having my car for a few days. I said you can have it for a month if you fix this problem!

So monday night after work the service manager told me to drop the car off and they are going to drop the transmission and take it apart to get to the bottom of this problem that has been driving me mad!

Finally some progress and not just doing this

 

[Mustang5L5]

and they are not going to find anything.


It's a design flaw in the synchros not slowing down the gears fast enough. Mechanically everything is going to look perfectly fine in there. The blocker rings might even look brand new.

The fix is a redesigned 2nd and 3rd gear that will grab and slow down more efficiently than the incorrect design. There is a kit and TSB for this if you don't have it. If you want a copy, email me [email protected]. If gives parts numbers for the redesigned gears and synchros. It's TSB 04-16-6

 

[smokin91']

and they are not going to find anything.


It's a design flaw in the synchros not slowing down the gears fast enough. Mechanically everything is going to look perfectly fine in there. The blocker rings might even look brand new.

The fix is a redesigned 2nd and 3rd gear that will grab and slow down more efficiently than the incorrect design.

So on monday do you recommend that I bring in the TSB and show them that as well???

 

[Mustang5L5]

I would bring the TSB with you. Need a copy? Give me an email and i'll forward

 

[Mossberg]

Common problem. I never had the TSB done though since I don't notice the issue anymore now that I moved down south to Georgia.

 

[Mustang5L5]

I've been lucky. I've never had the TSB done. 50K miles on my '03 and it's been a very consistent minor problem.

In the summer, first 1 or 2 shifts clunks and that's it.

in the winter on very cold days, first 10 mins is a clunk, but nothing bad enough to piss me off. After that it would shift fine.


I just never wanted my 3650 torn into, so i lived with it. In fact, i barely even notice it.

I want to change my trans fluid...but as the saying goes... "If it aint broke, don't fix it"

 

[smokin91']

Mine doesnt just clunk, it also grinds. Its a problem I cant live with.

Having the transmission torn into doesnt bother me. As long as I get it back fixed.

What is the COST of the parts for the TSB???

Like you said earlier it make look all good in there, but I want this TSB done and as a last resort I WILL PAY FOR THE PARTS myself if i have to. The labour and all that is covered under my warranty, im just worried they may find nothing wrong "Visually" and not do the tsb.

Anyone know what the TSB parts cost is?

BTW paying for the parts is a last resort. They are doing all the labour for free under warranty im just worried that they will visually find nothing wrong, in that case theres no way the transmission is going back together with NOTHING done to it. Ill eat the cost of the parts if I have to. A smooth shifting tranny would be well worth it.

 

[Mustang5L5]

The part number for the kit is 3R3Z-7124-AC and contains a new 2nd and 3rd gear, a new 1-2 synchro, a new 3-4 synchro, new blocker rings, new 1-2 shift fork, 3-4 shift fork and related shift rails.

Quite a bit of parts.

I head it's around $900, but maybe call up other ford dealers and ask em for the price of that part number

 

[smokin91']

Ok Im lookin at the TSB and I see all those parts listed under the part number that you listed.

900$ isnt that bad if it comes to that, but im going to try to get it all covered under warranty. Id rather pay 0$ then 900$ any day but sometimes u gotta take one for the team lol.

Im thinking about calling tremec and finding out more info pertaining to the problem. I need as much ammo as I can possibly get.

The hardest part is done though, getting the service manager to agree to take the tranny out and tear it down under my warranty. Actually I didnt have to get Him to agree, IT WAS HIS IDEA! go figure?

Just keep your fingers crossed for me, im not letting this DIE!

 

[smokin91']

I just got off the phone with a tech from tremec. He sent me a bunch of pictures of the new VS old parts and worn/new ones from the 3650. He told me that if it is grinding there will be visible damage on the synchros and the gears and it only gets worse. Once the teeth get grinded enough then it will start popping out of gear.

He said the number of calls they get regarding this issue with our cars is high and it is a more common problem then you think.

That makes me feel a little better knowing that when they open it up they are going to see there is something not right visually, which should be enough for them to do the TSB.

Ill post up the pics if anyone is interested.

 

[Mustang5L5]

Sure i'd love to see em.

 

[Skud]

I took mine in a awhile ago and I was lucky enough to me in the car with the service manager when it did it..

Out of the parking lot, first shift from 1st to 2nd "crrrunch"..

"Oh, yeah I see what you mean.. Don't know how they could have missed that.."..

Then I had the TSB done and it's been "OK" since then.. I still get a VERY light crunch when it's cold, but I don't drive it in the winter anymore so I don't worry about it..

Riley

 

[smokin91']

1-2 SYNCRO - ORIGINAL DESIGN 2ND GEAR SIDE


1-2 SYNCRO - NEW DESIGN 2ND GEAR SIDE


2ND GEAR ORIGINAL DESIGN CLUTCHING TEETH


2ND SPEED GEAR - NEW DESIGN - OFFSET CLUTCHING TEETH



Here are pictures of the wear that you will see however he said that these pics are from a T56, which is similar but I just wanted them as an example of what the synchros/gears should look like.


Good Synchro


Good Clutching Teeth


Bad Synchro


Theres also a picture of what a grinding gear will look like but its in .PDF format, if you want that let me know.

 

[Mustang5L5]

That's ok. I've rebuild t-5's before so i know what those look like. The differences between the new and redesigned parts were what i wanted to see thanks

 

[Pearl02]

I had my tranny repaired under the TSB a couple of years ago. Mine would grind horribly going into gear when the temp was below 30 degrees. The TSB repair fixed my grinding. I don't drive my car much during the winter months. It doesn't grind anymore. Pearl02.

 

[smokin91']

My car is my DD so it definatly gets driven in the cold. So far most of the people that have had the TSB done it fixes the problem.

Anyone had it done and it not fix the problem?

 

[Pearl02]

If the dealer does the job right you'll be happy with it. Pearl02.

 

[smokin91']

I dropped the car off tonight after work, and spoke to the service manager, He is the one taking care of all this for me.

I told him that I spoke to a tremec tech and gave him a printout of the TSB and the OLD vs NEW parts in the TSB kit. I also gave him the Tremec techs name and email address as well. He was really happy that I brought in the TSB.

So hopefully in a few days if all goes well I should have my car back! Minus the 1-2 Crunch.

 

[smokin91']

Ford called me at 1pm today. The service manager told me the tech took my transmission apart, and got as far as he could go. They ordered the Synchro kit as per the TSB and said the parts will be in tomorrow.

The dealership is open until 8 tomorrow night so hopefully I have my car back then. I cant wait to feel a smooth 1-2 shift!

Im going to ask the tech if I can have the old gears/synchros to post pics up here to show people that damage IS being done inside their transmission even with the slightest grind. If i cant keep the parts i will at least take pictures at the dealership.

Im sooo excited i cant wait to have my car back!

 

[2013 Geee T]

Ive had the TSB done and its much better but not perfect. Its worth having it done though.