Gearbox Issue - 2nd gear dead

[Smartguy67]

The above probably doesn't help really as Ford TSB's are mainly an extension to the service manual and not a guarantee they are going to pay for what is becoming a known problem.

I would be posting on their Puma site in Facebook saying what had happened and what steps have they taken to ensure this won't happen on the latest model. A gearbox should well outlast the life of the car.

[Mike]

Nephews partner has just had her Puma back from the dealers, started that 2nd gear would not engage suddenly. Dealer has replaced 1st, 2nd , 3rd and 4th gears and bearings , also had a new clutch fitted for some reason luckily covered by the warranty. Dealer said they have stopped replacing gearboxes due to the cost and they are seeing more and more with the same issue.

Good luck all with similar issues.

Would like to know if my Puma has had any issues since i sold it.

[4251]

This is very concerning! I haven’t heard of issues with the Focus so was wondering if the Puma 125/155 mhev’s use the Fiesta gearbox rather than the Focus/Mondeo gearbox? It’s easy enough to identify it; if reverse is to the right and back it’s a Fiesta box, if reverse is to the left and forward it’s a Focus box. If they’ve used the Fiesta box it’s suggesting it’s not up to the torque of the engine/weight of vehicle, especially being 2nd gear.

The 1.5 ST200 definitely uses a Focus type box

Changing synchro’s isn’t that bad a job and shouldn’t cost anywhere near the numbers being quoted , Alan Howett on YouTube has done a few Mondeo gearbox repairs. But after about 175K !

[Rrh]

Just reading all about this as we have a Ford Focus 2020 MHEV vignale and at the weekend we couldn’t get second gear! Reading all your posts, looks like we won’t have any warranty - bought second hand 2 years ago. It’s done 30k miles. Absolutely gutted - the most expensive car we’ve ever bought Taking it to the local Ford garage tomorrow for a chat….

[4251]

Is this the reason they dropped the 155 manual? I think more than a coincidence. So from being some of the most reliable engine and gearbox’s decades ago they now seem they are now one of the worst. Still some good engines currently, ironically these are Mazda based, 2.0/2.3. Unfortunately this won’t be a US market thing as very few if any manuals will be sold there making it easy for Ford to sweep it under the carpet and do absolutely FA about it, that’s about where we stand.

[Smartguy67]

Must be a growing number of failures or Ford wouldn't have issued a TSB for the synchromesh repair.

A gearbox, especially a manual, should be bullet proof and long outlive the life of the car.

Ford are getting tons of abuse on FB and it sort of makes you think; would you want to own a newer Ford out of warranty when failures of components which are wearing related are happening at much less than the 60k miles Ford are giving.

There is no servicing to be done on the gearbox and with the amount reported to date, Ford should be paying in full where mileage done is less than the amount given. There won't be many who are doing 20k miles a year in a Puma

[4251]

Must be a growing number of failures or Ford wouldn't have issued a TSB for the synchromesh repair.

A gearbox, especially a manual, should be bullet proof and long outlive the life of the car.

Ford are getting tons of abuse on FB and it sort of makes you think; would you want to own a newer Ford out of warranty when failures of components which are wearing related are happening at much less than the 60k miles Ford are giving.

There is no servicing to be done on the gearbox and with the amount reported to date, Ford should be paying in full where mileage done is less than the amount given. There won't be many who are doing 20k miles a year in a Puma

Yes your right. Seems all of Ford’s good engineers left the company years ago. They used to be the best gearboxes you could get years ago and they should last almost forever. They’ve managed to produce very poor DCT auto’s, 1.0 engines and now manual gearboxes in last few years, not to mention having an uncanny ability to not be able to stick seals and trim on! Plus make thousands of 2.3 engines over 2 years with the wrong head gasket fitted!!!!

[Mike]

Is this the reason they dropped the 155 manual? I think more than a coincidence. So from being some of the most reliable engine and gearbox’s decades ago they now seem they are now one of the worst. Still some good engines currently, ironically these are Mazda based, 2.0/2.3. Unfortunately this won’t be a US market thing as very few if any manuals will be sold there making it easy for Ford to sweep it under the carpet and do absolutely FA about it, that’s about where we stand.

Nephews partners car is a 125 and only 1.5 yrs old

[4251]

Is this the reason they dropped the 155 manual? I think more than a coincidence. So from being some of the most reliable engine and gearbox’s decades ago they now seem they are now one of the worst. Still some good engines currently, ironically these are Mazda based, 2.0/2.3. Unfortunately this won’t be a US market thing as very few if any manuals will be sold there making it easy for Ford to sweep it under the carpet and do absolutely FA about it, that’s about where we stand.

Nephews partners car is a 125 and only 1.5 yrs old

Yes, I see there is the odd 125 too, but already seems to indicate it is a gearbox strength issue and more 155’s involved. Going by the numbers it is looking like a very worrying problem

[PCarson]

Hi everyone, I see majority of issues seem to be with 2020/21 models but I am having huge issues with a May 2024 ST Line X model. Moving through the gears from 1st-3rd is particularly difficult, especially coming down the gears. It has been back in the showroom 5 times in 6 months and they have replaced parts of the gearbox and the clutch but to no avail. I have been driving Fords since passing my test over 20 years ago and I cannot believe what I am experiencing with a brand new car. The hand brake is also faulty and the advice from the garage has been to not use it but to stay in gear I really have no words.