Just wanted to share an issue, and its likely resolution. It started with an odd droning noise at around 30-40mph at about 59,000 miles on my car. My tires were nearly gone, so I attributed it to that. Fast forward a couple thousand miles to some new tires and guess what... noise not gone. In fact, it got much worse in the last week or so. By now, i'm at 63,000 miles. The noise seemed to be coming from the transmission area.
I took the car to my local dealer this morning for diagnosis. The mechanic confirmed the unusual noise on a test drive with me. They then did more work by attaching microphones around the engine bay to isolate the source. That part was super cool. They have nice toys there :)
The dealer's evaluation showed the noise to be likely coming form the right-side CV axle assembly. That drive shaft has a straight portion ("half shaft") that has a big bearing on it. Apparently, that bearing is going out and making lots of noise. Unfortunately for me, the drivetrain warranty is 60k. That extra 3k miles is looking to cost nearly $700. Ouch! Ironic how if it was the tranny, I'm covered for 150k <- one of the few benefits of living in CA.
I'll update my post once the repair is done and confirmed fixed. They had to order the CV axle. I'm hoping I can work a solution through the dealer/Ford for some goodwill on this one. I just hope the new axle lasts longer than 60k miles :)
UPDATE 1: The CV axle turned out to NOT be the major source of noise. I drove the car after they swapped it out and to me, it sounded the same. They insist that the bearing on the half-shaft was bad. I'll leave it alone as the thing already had 63k on it. I'll just consider it a "proactive" replacement :) In any case, they did some further digging and found metal shavings in the trans fluid. That's bad, in case you were wondering :) A new trans has been ordered and Ford will take care of it all under warranty. Can't wait. New trans arrives next week. In the meantime, my car sounds quite unhappy going down the road, but it runs. MPG doesn't even seem affected. Will update again once new tranny is installed. Can't wait...
UPDATE 2: Trans repair is well on its way. After 3 full days at the dealer, they're almost done. All that's left is some computer programming (program the new trans, i guess) and a wheel alignment. Should have my car back tomorrow. Almost there...
Edited by marcin, 06 February 2016 - 12:08 AM.