I have just bought a Mondeo ST 2006 model an been driving it about 2 weeks now And have started to notice a noise. When I change from 3rd to 4th gear their is a crunching noise coming from the gearbox, sometimes rarely happens from 2nd to 3rd. I thought it was my driving style at first adjusting to the new car. But no matter how easy I go it still makes a crunching noise!? Any one else experienced a problem like this?

could be signs that the DMF is starting to fail. Check the receipts and see if you have had a clutch / dmf replacement done?

@jeebowhite thanks for the reply. Would this also be noisy on tickover? When the engine is idling it sounds like there is a rattling coming from the engine somewhere but as soon as you rev the engine it's smooth!?

Sent from my iPhone using Ford OC

The rattling that you mention in post #3 does sound like DMF. Prior to reading that, I'd thought synchromesh getting worn or the gearbox oil going off (or, maybe, the clutch not disengaging fully). That would tend to make gear changes more difficult, so if gear changes are still fairly slick, it is more likely to be DMF.

If it was the syncromesh is that just a case of gearbox out and re building the lot?

Sent from my iPhone using Ford OC

Usually, if it hasn't gone too far, changing the oil, particularly for better, more modern oil, makes a satisfactory job of it. Re-building the gearbox would be fine, too, but there's a lot of work in that. Oh, and usually when synchromesh gets weak, it is second that goes first/worst (3rd in to 2nd), so that might also be evidence that it is something else.

How many miles has the vehicle done, and is there any evidence of clutch/DMF being done?

Appreciate you replying mate, car has covered 63,000 with a FSH but nothing about dmf or clutch? Oil change done recently but don't think the gearbox has been done. Had a speak with someone about the idle noise an they reckon common problem with alternator when it's under load it shudders! Think I am just going to have to take it into a garage get it checked out. Cheers again. Matt

Sent from my iPhone using Ford OC

I must admit, I went through the receipts on my Mondy (MK4) just after I bought the car. The mileage was around 63K when they had to do a full DMF Clutch replacement. Depending how it was driven before you took posession of it (and given its an ST, I doubt highly it was driven like a religious old womans car!) then I suspect you probably are looking at the DMF / Clutch

Think I am just going to have to take it into a garage get it checked out.

I think that's right. While I suspect that it is clutch/dmf, there is only so much that you can do via a forum. In this case it stops short of being certain.

One other thing; if you have a noise at idle, and it changes as you depress the clutch, that would almost certainly be DMF/clutch.

63 k would be a bit early for a gearbox problem, but, if someone drove it aggressively, who knows? On the other hand, people do think that you start to see DMF failures from about 80k, so while it is still a bit early for that, it isn't by all that much. And, you can accelerate DMF wear-out by driving badly, and that isn't the same as driving aggressively; some of the worst will be those who think that, because they have a diesel, they should be able to pootle around at 1400 rpm in any gear (I don't know where that idea comes from).