hey folks, i have a factory manual EF wagon, i replaced the clutch yesterday and noticed that the gearbox now whines in 1st and 2nd gears. well its not really a whine, more of a linear and subtle rumble or whirr sound. it can only be heard with the windows up and radio or because its very quiet.

it happens when 1st or 2nd gears are engaged regardless of clutch engagment although it does get loud the more you rev her. i also removed the shifting levers rubber bushing in favour of a DIY metal one which could be accentuating existing gearbox vibrations. hoping its not bearings but you would think it would of happened before the clutch was replaced too?

cheers

Welcome to fordmods.

Did you replace the spigot bearing in the centre of the flywheel? If it was damaged during the gearbox installation then it will create a whine.

thanks, i did replace the spigot but i used a socket and tapped it lightly into place, i made sure not to damage it.

the noise happens when either 1st or 2nd gear is engaged in the gearbox, regardless if the clutch is in or out. say if its in 3rd and i press the clutch and drop it into second but hold the clutch in, it will start making that whirring noise so it cant be the spigot right?

anyway heres a video, you can quite clearly hear the whirring in 2nd predominantly. https://www.youtube.com/watch?v=iJizU7ZJ6X0

From the repair manual, the causes could be:

- worn front bearing
- chipped or pitted mesh gears
- excessive laygear end float (that's the gear on the end of the input shaft that turns the counter shaft)
- insufficient transmission fluid
- worn spigot bearing

With the clutch disengaged, the flywheel is still spinning the spigot bearing around the input shaft.

Did you check or top up the transmission fluid?

Trans fluid was at the correct level when I drained it out and appears to be correct stuff, I put back fresh dextron 3.

Thanks for the help, I think it must be excessive play internally.