Grinding, shuddering, hesitating

[petehouk]

Greetings everyone. I have a 2017 that's done 60,000 trouble free miles. But after I got off the highway on my way to work Thursday, I started hearing a noise like a big truck engine braking. This didn't seem like a problem since there were a few big trucks ahead of me. After they pealed off and I was alone on the surface streets I noticed I was still hearing this engine braking sound every time I slowed to a stop and had a genuine moment of panic when I realized MY CAR was making that noise.

I coaxed it into the parking lot at work. When I start from a stop, it hesitates, like it's stuck on something, and then it eventually goes. When I get it up to speed and let it slow down, it makes a shuddering and grinding noise. Also no lights, no warnings. Even with all that noise, I managed to get it over to the dealership (2 miles). On the drive, I thought that it was sounding a little better when I decelerated if I put it in neutral. The service adviser and I took it for a drive and it sounded really bad. So at least this isn't an intermittent thing.

The dealer has now had the car since Thursday morning but they haven't been able to tell me what's wrong. Couple questions for this group:

1. What is likely to be causing this problem?
2. Is there someplace else I should be taking my car to? I'm in Southeast Michigan. If there's a shop in the area that has some expertise with the Focus BEV, I would be able to get it to them.

Thanks

Pete

 

[Heima]

I am afraid that I have no clue as to what the problem is. Parking pawl dragging?
Anyway, bear in mind that when the vehicle is in neutral, the motor is still engaged with the drive wheels. The gearbox is a constant mesh, single speed. There is no neutral like a manual transmission on automatic transmission has.

 

[Anti_Climax]

I believe some other folks have mentioned the gear/transaxle off the motor failing in a way that made it very noisy. I'd expect that to impact the amount of power it takes to get moving as well. If that's what it is, I believe replacement is the only real option. Should that be it, I'd recommend finding one that's been junked.

 

[petehouk]

I believe some other folks have mentioned the gear/transaxle off the motor failing in a way that made it very noisy. I'd expect that to impact the amount of power it takes to get moving as well. If that's what it is, I believe replacement is the only real option. Should that be it, I'd recommend finding one that's been junked.

Yeah this thread (link below) sounds like my problem. I actually described it to the service tech as "sounds like engine braking".

Is this common? I'm willing to have a go at replacing the edrive with one from a junkyard, but I don't want to go to all that trouble if I run a real risk of getting another broken unit from them. I would like to drive it before they pull it but that's probably wishful thinking. Any thoughts on what to inspect for before I install it?

Also, "electric motor and gearbox" are called out in the 8 years/100,000 mile coverage section of the 2017 warranty documentation. I'm going to ask the dealer to replace this one for me.

https://www.myfocuselectric.com/threads/engine-braking-sound.5065/

 

[Anti_Climax]

It's DEFINITELY in the drivetrain. If you need to pull one, you'll only find it on the electric. You'd likely be able to tell what shape it's in if you can spin the wheels back and forth. If you hear anything it's likely to be bad. That said, I don't think it's terribly common.

 

[petehouk]

My appointment with the dealer isn't until September 30. I didn't drive the Focus this past week because the sound had been so bad. (70 mile round trip commute.) But my wife is starting to get tired of me taking her car to work.

I checked out all 4 corners and the hubs did not feel sloppy. I replaced the brakes while I was in there too so I know it wasn't that. All this is to say I'm thinking about driving it this week. Is there a chance of making this thing more broke than it already is? If the remedy is to replace the motor and gearbox, then I don't see how it can get any more broke. I guess I might get stranded, but it doesn't sound like driving the car is likely to turn this from a small repair into a big repair--it's already a big repair!

Also, which warranty is this covered by? Here's an excerpt from the warranty guide describing the Powertrain warranty:

Extended warranty coverage periods are available for certain vehicle parts and conditions. Specifically,(1) Your vehicle’s Powertrain components are covered for five years or60,000 miles, whichever occurs first. The extended coverage applies to the Engine: all internal lubricated parts, cylinder block, cylinder heads, electrical fuel pump, powertrain control module, engine mounts, flywheel, injection pump, manifold (exhaust and intake), manifold bolts, oil pan, oil pump, seals and gaskets, engine thermostat, engine thermostat housing, timing chain cover, timing chain (gears or belt),turbocharger/supercharger unit, valve covers, water pump; Transmission: all internal parts, clutch cover, seals and gaskets, torque converter, transfer case (including all internal parts), transmission case, transmission mounts; single-speed gear (for The Focus Electric);

And here's an excerpt describing the hybrid/EV components coverage:

(4) Your vehicle’s unique hybrid / electric components are covered during the Hybrid / Electric Unique Component Coverage, which lasts for eight years or 100,000 miles, whichever occurs first.
• The following hybrid parts are covered during this extended coverage period: high-voltage battery, hybrid continuously variable transmission, Inverter System Controller (ISC), DC/DC converter, high-voltage battery connector, battery pack fan assembly, thermistor probe, Hybrid Battery Pack Sensor Module (HBPSM), Battery Energy Control Module(BECM), and the PHEV onboard charger.
• The following plug-in-vehicle unique parts (if equipped) are covered during this extended coverage period: high-voltage battery packs, high-voltage charger, DC/DC convertor, electronic drive module assembly (includes electric motor and gearbox), transmission range sensor, and charge cord.

The way I read this, the drive motor and gearbox are covered for 8 years/100,000 miles, so this work should be covered. Still I'm expecting some pushback from the dealer. Hopefully I'm wrong about that.

 

[Anti_Climax]

There no real question it's under coverage. Whether they decide that's the case is entirely separate.

 

[CheesecakeLover]

Sounds like the transmission, hopefully still under warranty!

 

[petehouk]

I finally go tit in for the appointment yesterday. The service adviser agrees that it is either the transmission or the motor and that it's covered under warranty. He also said there is no time estimate for how long it will take to get a replacement...

 

[Anti_Climax]

Yeah, that's on Ford corporate. Being rare as these are, they don't keep a lot of the parts on hand to ship immediately.