2.3 manual noise when engine is cold

CGBadlands21

Jan 12, 2022

Had my Bronco a couple months. 2000 miles. I have the 2.3 manual in my Badlands. When I start it up in the morning I hear what sounds like a grinding, somethings loose kind of noise. When I push the clutch in it seems to go away. It also seems to go away after it has been driven a while. Anyone else experiencing this? Is it normal? I have an appointment to bring the truck in tomorrow 1/12/22. I will let everyone know how I make out.

2021 Bronco Badlands
Cactus grey
Lux Pkg 7spd

Roughstock11, F1ATX

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Dec 31, 2022

#140

The TSB only replaces the 5th and 6th gear synchros in the transmission with the same exact parts that are already installed from the factory. There hasn’t been a part number revision for those synchros yet.

There are many many instances of other Bronco owners on the internet who’ve either had their 7MT replaced entirely, or had the TSB work done, and have the grinding come back either immediately or after a few hundred miles.

Hopefully Ford actually makes a revision on these parts and fixes the issue, or revises the transmission fluid spec, or something that resolves the issue entirely instead of just kicking the can down the road.

I’m starting to have Focus RS head gasket and timing chain cover flashbacks 😅

extra toasty, Bronco 202?

Jan 01, 2023

#141

SPITmadFIRE
The TSB only replaces the 5th and 6th gear synchros in the transmission with the same exact parts that are already installed from the factory. There hasn’t been a part number revision for those synchros yet.

There are many many instances of other Bronco owners on the internet who’ve either had their 7MT replaced entirely, or had the TSB work done, and have the grinding come back either immediately or after a few hundred miles.

Hopefully Ford actually makes a revision on these parts and fixes the issue, or revises the transmission fluid spec, or something that resolves the issue entirely instead of just kicking the can down the road.

I’m starting to have Focus RS head gasket and timing chain cover flashbacks 😅

Amen! I’m trying to get my dealer to research this before letting them work on the trans. If it’s been addressed at the vendor, then I’ll get in line.
Someone needs to have answers to this….

22 Badlands 2-door, 7MT, HP Red, delivered Nov 2022
Former fords: '83 Mustang Conv, '94 Bronco XLT, '05 Excursion PSD, '10 Expedition EL EB (still the family wagon).

Bronco 202?

Jan 01, 2023

#142

Had our 2021 BL MT since September 2021. I think we might of had a grindingish noise when new during cold start in cool weather but if so it went away long time ago. Likely a break in noise. Give it some time and should hopefully go away on its own. As of today our MT still runs perfect minus a bit notchy going into 1st.

*Also, its not natural but try to avoid pressing gas pedal when releasing clutch in 1st gear from a stop...you dont need to do it. Just release clutch. Bronco will propel forward on its own without stalling, at least with 4.70 rear gear found in Badlands trims + doing so will prolong your clutch life. It takes some getting used to compared to previous MT cars we've owned but its the only way we drive bronco now.

2021Bronco☆2.3☆BL☆7MT☆4D☆A51☆SoftT☆ARRIVED 9/9/21☆SOLD 1/21/23☆NT Supports▪Consults▪Supply's Car Dealers, Vehicle Distributors, and Retail Customers Since 1992

Jan 01, 2023

#143

NT AUTOMOTIVE
Had our 2021 BL MT since September 2021. I think we might of had a grindingish noise when new during cold start in cool weather but if so it went away long time ago. Likely a break in noise. Give it some time and should hopefully go away on its own. As of today our MT still runs perfect minus a bit notchy going into 1st.

*Also, its not natural but try to avoid pressing gas pedal when releasing clutch in 1st gear from a stop...you dont need to do it. Just release clutch. Bronco will propel forward on its own without stalling, at least with 4.70 rear gear found in Badlands trims + doing so will prolong your clutch life. It takes some getting used to compared to previous MT cars we've owned but its the only way we drive bronco now.

There are examples of how the 5th and 6th synchros look after completing the TSB, and a significant amount of material gets shaved off of them as a result of this issue. I think it’s pretty unreasonable to claim a known issue with a TSB available can be chalked up to “break in” just because your noise has gone away for now. There are dozens of folks experiencing this issue well above the break in period, including myself at 10,000 miles.

Nfauv06, Bronco 202?

Jan 01, 2023

#144

Update: Picked up my Bronco on 12/23 after having transmission replaced. Drove it 3 times and ‘the noise’ started again. Brought it back to the dealer. They informed me the TSB came out after they replaced my transmission. The ‘fix’ parts have been ordered and they told me I could drive it safely until the parts come in. Will update when new parts are installed.

Nfauv06, Laura

Jan 01, 2023

#145

SPITmadFIRE
There are examples of how the 5th and 6th synchros look after completing the TSB, and a significant amount of material gets shaved off of them as a result of this issue. I think it’s pretty unreasonable to claim a known issue with a TSB available can be chalked up to “break in” just because your noise has gone away for now. There are dozens of folks experiencing this issue well above the break in period, including myself at 10,000 miles.

Not chalking up anything. Just sharing our own Bronco BL MT experience the last 17 months. Our optimistic position is aimed more at helping give some out there a little hope in the product.

We also never use 5th or 6th gear. You can go 100mph in 4th gear. So maybe just avoid 5 & 6 as much as possible. Higher revs also better for the clutch...but not better for mpg haha.

No one appears to have an answer including the guy on his 3rd tranny still hearing the noise. So maybe try ignoring it for a little while and/adjusting MT driving habits a little to see if it goes away. Worst case still have 1-2 years worth of warranty left to MAYBE fix it if sound doesn't go away before OEM coverage expires.

2021Bronco☆2.3☆BL☆7MT☆4D☆A51☆SoftT☆ARRIVED 9/9/21☆SOLD 1/21/23☆NT Supports▪Consults▪Supply's Car Dealers, Vehicle Distributors, and Retail Customers Since 1992

Jan 01, 2023

#146

NT AUTOMOTIVE
We also never use 5th or 6th gear. You can go 100mph in 4th gear. So maybe just avoid 5 & 6 as much as possible. Higher revs also better for the clutch...but not better for mpg haha.

problem is noise does not show up in 5th or 6th. It shows up on cold idle in neutral and when moving in 1st and 2nd when cold. When idling if you take the shifter towards 6th without depressing the clutch the noise stops as the synchro is engaged. Best way to describe the sound when moving is like and old manual truck with a non synchro transmission moving in reverse but louder. My biggest concern with the keep driving it solution is what if the wear it’s causing leads to the back end of the transmission going grenade mode at highway speeds and possibly causing the rear axle to lock.

22 Black Diamond 2dr non sas w tow and roof rails.

SPITmadFIRE

Jan 01, 2023

#147

dover157
problem is noise does not show up in 5th or 6th. It shows up on cold idle in neutral and when moving in 1st and 2nd when cold. When idling if you take the shifter towards 6th without depressing the clutch the noise stops as the synchro is engaged. Best way to describe the sound when moving is like and old manual truck with a non synchro transmission moving in reverse but louder. My biggest concern with the keep driving it solution is what if the wear it’s causing leads to the back end of the transmission going grenade mode at highway speeds and possibly causing the rear axle to lock.

Not a Ford mechanic but pretty sure the trans won't grenade because of a bad synchro. Just annoying grind sound and a bit harder or NA to shift the stick into affected gear. I wonder why 5th and 6th need replacing per the TSB but it happens in neutral/1st/2nd. Am curious has anyone with the TSB issue noticed any difference in how the bronco drives or is the issue solely an annoying sound?

2021Bronco☆2.3☆BL☆7MT☆4D☆A51☆SoftT☆ARRIVED 9/9/21☆SOLD 1/21/23☆NT Supports▪Consults▪Supply's Car Dealers, Vehicle Distributors, and Retail Customers Since 1992

Jan 02, 2023

#148

CGBadlands21
Had my Bronco a couple months. 2000 miles. I have the 2.3 manual in my Badlands. When I start it up in the morning I hear what sounds like a grinding, somethings loose kind of noise. When I push the clutch in it seems to go away. It also seems to go away after it has been driven a while. Anyone else experiencing this? Is it normal? I have an appointment to bring the truck in tomorrow 1/12/22. I will let everyone know how I make out.

New member here... im replying here because my '22 AT (2.3L) is experiencing what seems to be a similar issue. I bought from a Subaru dealer in NC at 1200mi., and I'm at 5200 miles now. Noticed this new rattle @~4200 miles. Like everywhere, it's been cold here in TN, and my first 2-3 miles from home are up a couple pretty steep climbs. When I have the gas pedal firmly engaged and gearing slides from 1st to 2nd & 2nd to 3rd in the to 2-3k rpm range, I hear and feel (deep in the shifter) a progressive rattle/jarring noise. I'm essentially compresing pedal ~75% the to floor and getting to ~45 mph. I'm having some diagnostic work done at the local dealer now, and they've agreed that there is an issue, but have yet to pinpoint to problem/parts. It definitely seems to be during the gearing transition. Ring gear in there perhaps?

Is anyone experiencing the same on the AT?

Jan 02, 2023

#149

RockyMountainBoiler
Is anyone experiencing the same on the AT?

Automatic Transmissions and Manual transmissions are so different that anything said in this thread regarding their Manual Transmission could never apply to the Automatic one.
Ensure your transmission is up to normal temperatures before attributing any noise to it. When things are cold, the lubrication doesn't get where it should as fast, and pressures won't be what they should be until things warm up.

2D Base Mansquatch: Ord 11-24-2021; VIN 3-16-2022; Schd 5/9/22; Sticker 5/4/22; Modules 5/10/22;Built 5/11/22;Shipt 5/12/22;Delv 5/24/22

Deano Bronc

Jan 05, 2023

#150

Fillups
Adding myself to this list / subscribing as well. I have had my 2-door badlands 7MT for about 6 weeks now with just over 700 miles and this noise had been driving me crazy. I call it a scraping or grinding noise when letting the clutch out in neutral, but there is also a rattling sound when accelerating in 1st and 2nd gears. It may be all gears, but the road noise drowns it out beyond 2nd gear.

Took me a while to find this thread here, mostly read the "general" forum. But I have read similar threads on the other form also, so recently became aware. I have mixed feelings about this last part - replacing parts? I'm not keen on a dealer tearing down a trans with under 1K miles on it. This thread started long time ago and my Bronco was just delivered last month, so this seems to be very "hit or miss" and if they figure it out on the supplier side, I think I'll be pushing for a new trans. But I'll keep reading in meantime. Thanks to all that have shared.

There is a Ford TSB on manual transmission. Replace synchronizers and about 20 other parts. Mine just got done. You need to go to dealer ASAP as many parts are on back order.

Jan 06, 2023

#151

Brocky
There is a Ford TSB on manual transmission. Replace synchronizers and about 20 other parts. Mine just got done. You need to go to dealer ASAP as many parts are on back order.

The TSB unfortunately doesn't seem to solve the issue. There are a handful of people on another forum who have taken their Broncos in for the TSB _and_ a full transmission replacement, and they're all experiencing the same issue only a few hundred miles later.

Jan 06, 2023

#152

SPITmadFIRE
The TSB unfortunately doesn't seem to solve the issue. There are a handful of people on another forum who have taken their Broncos in for the TSB _and_ a full transmission replacement, and they're all experiencing the same issue only a few hundred miles later.

Great. You just changed my state of mind! Now I’m pissed. Hope this doesn’t happen to me. Thanks for the info.

SPITmadFIRE

Jan 06, 2023

#153

Brocky
Great. You just changed my state of mind! Now I’m pissed. Hope this doesn’t happen to me. Thanks for the info.

Sorry for the bad news -- let us know either way if your noise has gone away for good or if it comes back! We're all in this together 🥲

Jan 06, 2023

#154

SPITmadFIRE
Sorry for the bad news -- let us know either way if your noise has gone away for good or if it comes back! We're all in this together 🥲

@Brocky
….Yes, please keep us updated after the TSB work was done. I’m the one (or one of) on my 3rd transmission and been offered a 4th. Very curious whether or not the TSB recommendation is an actual long term repair.

Jan 16, 2023

#155

Just dropped my bronco off at the dealer, noise was getting worse and had become very noticeable when moving in 1st or 2nd when cold in the morning. They advised at least a week before a tech can diagnose it. Just over 6300 miles. Hopefully they get it fixed the first time.

22 Black Diamond 2dr non sas w tow and roof rails.

Fillups

Jan 17, 2023

#156

dover157
Just dropped my bronco off at the dealer, noise was getting worse and had become very noticeable when moving in 1st or 2nd when cold in the morning. They advised at least a week before a tech can diagnose it. Just over 6300 miles. Hopefully they get it fixed the first time.

Interesting to read your description - I'm still under 1K miles and noticed this weekend that mine is also getting louder and more noticeable, even after being warmed up. I was idling thru some parking lots yesterday (engine at normal operating temp) and the rattling sound does not go away oncie the clutch is pressed. Grinding noise in 1st and 2nd and also after clutch is pressed while rolling to a stop, then the grinding slows and stops. I also feel and hear a "clunk" when pressing the clutch accelerating out of 1st and 2nd - I'm assuming that is related and worry about wear all throughout the transmission.

Thanks for the update and keep us posted please. I'm curious if they work the TSB repair or replace your transmission, assuming the internal issue has been addressed by the vendor (Getrag?).

22 Badlands 2-door, 7MT, HP Red, delivered Nov 2022
Former fords: '83 Mustang Conv, '94 Bronco XLT, '05 Excursion PSD, '10 Expedition EL EB (still the family wagon).

Jan 19, 2023

#157

I had my Bronco at the dealer for an unrelated repair. Apparently the tech that drove my Bronco after it was fixed noticed a noise in neutral. I've never noticed any noises. They ordered the parts since there is the TSB. When the parts come in they'll call me. I still haven't heard anything.

2022 Bronco Black Diamond 2dr 2.3L manual Hot Pepper Red. Reserved 8/7/20. Ordered 1/23/21. Reordered 10/08/21. Scheduled week of January 24th 2022, delivered 2/24/2022

Deano Bronc

Jan 19, 2023

#158

NT AUTOMOTIVE
Not chalking up anything. Just sharing our own Bronco BL MT experience the last 17 months. Our optimistic position is aimed more at helping give some out there a little hope in the product.

We also never use 5th or 6th gear. You can go 100mph in 4th gear. So maybe just avoid 5 & 6 as much as possible. Higher revs also better for the clutch...but not better for mpg haha.

No one appears to have an answer including the guy on his 3rd tranny still hearing the noise. So maybe try ignoring it for a little while and/adjusting MT driving habits a little to see if it goes away. Worst case still have 1-2 years worth of warranty left to MAYBE fix it if sound doesn't go away before OEM coverage expires.

That's the worst advice I've ever heard. You aren't experiencing what everyone else is so maybe you shouldn't give advise.

BB - 2dr - mansquatch - VB

Bronco V-8

Jan 20, 2023

#159

21 Big Bend, 16k miles, same issue here. I just took mine in and the dealer said to rebuild the transmission or get a new one.

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