It had to happen sooner or later!

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bikeboyz
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It had to happen sooner or later!

Post by bikeboyz »

My 504 has been on the road now for 2 weeks, and 400 miles. Its a 2.3 diesel with 4 speed manual. Everything has run fine until two days ago. The unknown noise has started, which I cannot pin point. Its muffed by the cabin, but with the window open very defined.
1) Metalic chafing sound
2) Engine speed dependant
3) Loudest when at a constant speed of 35mph.
4) At tick over, not noticable, slight increase in engine speed generates the noise (parked head under bonnet!)
5) Seems to be coming from the back of the engine flywheel end.
6) When slowing down, for a junction/lights etc the noise goes away.
I have checked the oil level in the gearbox which is fine. Disconnected the alternator belt and driven but remains (because it sounds like a dry bearing). The engine is not using any unexpect amounts of oil. It has been suggested either -
1) Main shaft bearing in gearbox, or release bearing.
2) Engine's rear main crankshalf bearing has a loose cap
3) Loose flywheel
Any suggestions or experences on this? thanks Mat.
beezer
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Post by beezer »

Does it stop when the clutch is disengaged?
mbunting
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Post by mbunting »

2) Engine speed dependant
3) Loudest when at a constant speed of 35mph.
Can you please clarify the above, if it's engine speed dependant, you should be able to clearly hear it at whatever speed but at x rpm, or are we talking 35mph whatever gear ?
bikeboyz
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Post by bikeboyz »

No you can still hear it but not very loud when you have the car stationary when running.
You can hear it at all motion/engine speeds, but can be heard the loudest when at about 35mph, in top gear (4th) which has very little load on the engine.
After a nights sleep if it does turn out to be the box, does anybody know if the 505 auto box was the same as the 504? Might want to convert back to auto.
paradox
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Post by paradox »

Don't convert it back to auto!
I just sold my 504 Ti recently and shudder at the thought...
I have a feeling the 505 auto is different to the 504 auto, but I could well be wrong.
Put a BA10 or BA7/5 five speed box in there...
Is it difficult finding 504 parts in England?
beezer
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Post by beezer »

If the noise is still there when the clutch pedal is depressed then it is unlikely to be the box. It was a simple question. Good luck.
bikeboyz
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Post by bikeboyz »

I know both 504 and 505 auto boxes were ZF 3 speed, and I know a 5 speed manual box will fit with shorting the prop. The auto box would appear to have slightly higher ratios which would help with the diesel. According to Guinness World Car Records the Diesel Automatique goes quicker and faster with the 2.3D engine than the manual. Most of my driving is in town and she's a heavy beast, so kind of like the thought of the auto doing all the work!
Finding general parts for 504 isn't a problem, dealers can still order lots of stuff and there are several specialists who have had everything from new doors to gaskets! Petrol engines were common with 505 and 504 pickup trucks so no problem there. Diesel engines were also used in Ford Sierra in 2.3D format. Gearbox might be an issue for 504 if they are unique which is the pending question, I know diesel pick up trucks used the 5 speed, but I assume this is a BA7/5 which will be too big for the saloon.
paradox
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Post by paradox »

BA7/5 too big for the saloon?
I'm pretty sure this is not true. I believe they have managed to fit BA7/5's to 504s in Australia, possibly with minor modifications.
bikeboyz
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Post by bikeboyz »

I'm told it mean shorting the prop shaft, which is concealed in its own tunnel. On BA7/5 I think the 5th gear makes the entire box slightly longer.
Image
I have read on Aussiefrogs.com about people doing this mod and it would appear that you need to modify a few things.
The other thought is to drop in a 505GTD Turbo engine and gearbox, maybe auto, giving it 2.5TD, although the same prop issue might be there. I have seen TD engined ones on ebay in America, but think these are 2.3TD from old 604s.
bikeboyz
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Post by bikeboyz »

Well the pound signs in my mind have gone.... first day of day light that I have been able to really get it all to bits, and it turns out to be something simple. A dodgy exhaust manifold bracket! Phew!
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