Ok guys, i had some strange issues after having bluefin remap (100ps to 140ps) installed for around a year. 1st gear started grinding as it was going in, so i removed the map for a while, problems went away. Re-installed the map, and after a few months 2nd gear started grinding as it was going in after a few months of normal re-mapped behaviour. I removed the the map and all as ok, left it a month, reinstalled the map and it was fine again for a while, then it started gridning 2nd gear again, and now it's doing it with or without the map.

Took it to ford (with the map removed) and complained about the problem under warranty. They confirmed that the synchro has failed and apparently 1st and 2nd share the same synchro? Do you think it was just a bad synchro from the factory and the extra power just made the synchro fail earlier than it would have done anyway? Does the red/black 140ps edition use the same gearbox. Does the 100ps and the 125ps use the exact same box?

And finaly, has anyone else with a map had worm synchro issues?

Cheers guys.

If it's to do with the map it will be because the standard car will have torque limits for 1st and 2nd gear, these are usually taken out by other maps, they end up feeling more lively than the OE or mountune maps.

Are they going to fix it under warranty? They should do aslong as they don't suspect the car was mapped.

Yeah, maps off the car and just awaiting parts. So you think it's the bluefin map? Not good they are selling a map that will wreck a gear box so quickly.

it probably never crosses their minds, people buy the maps for the power and torque output,

40 ps increase is probably too much extra - normally 20% increase is considered safe.

What do Superchips have to say about the issue ?

Going to email them and see. The engine map for the 100ps goes to 140ps. The map for the 125ps goes to 150ps i believe. Now, if they are the same gearbox between the two models, wouldn't that mean that the guys running at 150ps should have had gearbox failures and issues cropping up?

It'll be the extra torque not BHP.

Agreed. . I'm not convinced these 3 pots with the standard clutch are up to it.

Understood. After reamp the 100ps goes from 170nm to 238nm and the 125ps goes from to 200nm to 234nm. The variation in the numbers i'm assuming is due to the fact not all engines output the same figures, 4nm shouldn't be the deciding factor here. So, any ZS remapped owners having any issues?

It is possible that the issue is unrelated to the remap ?

Although I do think that the extra bhp/ ps / torque could be an issue.

I suppose it is possible that the synchro is bad from the factory, and the extra power just happen to exasperate the synchro and cause the bad part to fail more quickly. All other gears are fine.

Ford warranty the MP135 which takes the toque to 214Nm they don't warranty the MR165 which is 245Nm.

Reason I mention this is, when I was at ford fair last year talking to Ken from moutuneusa, he said the stage 2 kit for the ST (MR230) wouldnt be a warranty approved MP kit as ford were worried about the transmission. Now moutune wouldn't remove th torque limiters but still it couldn't get warranty approval.

Plenty of people will say they have more power and are ok on standard clutch etc but have they done the testing ford can do?

The mileage my car is low at 27K. MR does invalidate the warranty, but they are well respected tuning company and i wouldn't of thought they'd use torque figures that could kill the transmission(sort of) in a year. I don't know, just hard to work out if its bad parts or too much power for the box to take.

It's a bit hit & miss really - stripping down the box & clutch may reveal the cause - extreme I know.

I'm assuming they haven't actually stripped it down yet. The mechanic will have just diagnosed a synchro failure, which i'm sure it is. I bet the 140ps red/black edition has the same box (adjusted ratios) but with a torque limiter on 1st/2nd gear.

The torque limiter would almost certainly prevent your symptoms, is yours not equipped with a torque limiter ?

I think the torque limit is set in the map, and i've heard that most engine maps remove this limiter.

140 is the same b5/ib5 box and same gear ratios, probably just a bad 1/2nd gear hub assy, it happens. my focus 140 uses the same box,(slightly different gear ratios) and my box fine

I have to say my Mondeo has Bluefin & I treat it with kid gloves in 1st & 2nd.

Different car / engine I know, but the principle is the same.

no such thing as a torque limiter, basically all the map does is slows the boost pressure build up by altering the wastegate duty cycle low down the revs

so you have lower boost pressure in 1st and 2nd gear up to 2500rpm approx, the boost curve therefore is calculated for each gear, 3,4,5 has a higher boost curve.

its not that noticable on the 1.0 ecoboost. its not excatly going to cause torque steer.lol

Torque output is nevertheless limited in at least 1st gear & possibly 2nd too ?

Torque limiters do exist ( Google it ) - whether the 1.0 ecoboost is electronically or mechanically limited I know not.

no such thing as a torque limiter, basically all the map does is slows the boost pressure build up by altering the wastegate duty cycle low down the revs

so you have lower boost pressure in 1st and 2nd gear up to 2500rpm approx, the boost curve therefore is calculated for each gear, 3,4,5 has a higher boost curve.

its not that noticable on the 1.0 ecoboost. its not excatly going to cause torque steer.lol

Torque limiting in first and second gear is done by the map basically as you've said above.

Torque limiting in first and second gear is done by the map basically as you've said above.

yep, ive altered my last cars map due to boost limiting in 1st and second, also the steering angle sensor had an input to limit boost in first 3 gears.

was all there to control 256hp delvery through front wheels,soon altered that so i had gradual boost but higher with alot higher boost and ign timing at 3000-5500, , that was in all gears.

tweekd to 320bhp through front wheels, was an animal but fun.

I'm assuming they haven't actually stripped it down yet. The mechanic will have just diagnosed a synchro failure, which i'm sure it is. I bet the 140ps red/black edition has the same box (adjusted ratios) but with a torque limiter on 1st/2nd gear.

Yes, exactly. This is probably the main reason why ford won't warranty past 140ps..

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