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1995 Feroza Hard knocking sound when accelerating


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greystroke
New User

Feb 28, 2015, 4:28 PM

Post #1 of 9 (1977 views)
1995 Feroza Hard knocking sound when accelerating Sign In

Year 1995
Make Daihatsu
Model Feroza F300
Engine 1.6
Kilometers 207k

Hi guys, my little rosy has developed a really bad rhythmic clunking sound recently, need some help identifying where the problem is. It's happening only when accelerating and gets faster and louder as I accelerate more, goes away if I push the clutch in. Had the car up on stands today to see if it were the cv's but doesn't seem likely as it still happens when the front wheels aren't being engaged. Tried turning the rear wheels manually to see if I could hear anything in the diff but no luck, maybe I couldn't turn it fast or hard enough. I had the rear diff pinion oil seal changed yesterday, could just be coincidence but either way am not terribly happy about the whole thing. Am hoping it's not the gearbox, it's about the only place I can't check at the moment.

Can definitely feel the knock if I put my hand on the rear diff when accelerating but can't tell if it's coming from there or vibrating down the drive shaft.

If anyone has any ideas please let me know.


Discretesignals
Ultimate Carjunky / Moderator
Discretesignals profile image

Feb 28, 2015, 5:04 PM

Post #2 of 9 (1969 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

Without being there to hear what your listening to and attempting to pinpoint the location, your guess is good as ours.

Did this noise appear right after the seal was replaced? They could have the pinion bearing preload too loose. Grab the pinion flange and see if it has too much up/down and in/out play.





Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.

(This post was edited by Discretesignals on Feb 28, 2015, 5:06 PM)


Tom Greenleaf
Ultimate Carjunky / Moderator
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Mar 1, 2015, 12:01 AM

Post #3 of 9 (1953 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

^^^^ Pic was there......
Appears like a Suzuki type vehicle to me?


Totally not familiar with this car not sold by that nameplate to the US so must ask and clarify words used. Hope that pic shows above as a sample of what this vehicle layout would be.


By "cv's" do you mean u-joints or real CV joints? How the heck (I'm trying to envision this) do you put your hand on a differential while accelerating without hanging under this thing? Do you mean just raising the RPM without load instead just while sitting there?


As DS mentioned noises are always tough without being there. To me using the word "knock" and while accelerating suggest it's load that makes it happen. Have you ruled out the engine itself as the source of noise?


Plenty of miles for a lot of possibilities,


T



(This post was edited by Tom Greenleaf on Mar 1, 2015, 12:06 AM)


greystroke
New User

Mar 2, 2015, 11:29 PM

Post #4 of 9 (1911 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

Ok here's a vid of the car in motion, you can clearly hear the sound. Just got the car back from the mechanic, looks like a broken tooth on one of the gears in the rear diff.
http://youtu.be/Ys9LhaVhoJ0


Tom Greenleaf
Ultimate Carjunky / Moderator
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Mar 3, 2015, 12:04 AM

Post #5 of 9 (1908 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

OMG - Sounds like a carpentry project going on in there!


Hey - if mechanic heard that in person it beats anything I could suggest and if a differential in trouble to make noise like that may self destruct at any time which will take the guess work out of what's making the noise.


Hey - careful driving on the 'wrong' side of the road like that - just kiddingWink


T



greystroke
New User

Mar 5, 2015, 2:25 PM

Post #6 of 9 (1884 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

Ok problem found https://www.dropbox.com/.../20150305_144900.jpg

Finding a replacement ring gear for this vehicle seems to be pretty much a lost cause these days. Looking to have the gear fabricated by gear cutting specialist


Tom Greenleaf
Ultimate Carjunky / Moderator
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Mar 5, 2015, 2:55 PM

Post #7 of 9 (1881 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

That will make your day I'm sure!


OK - What does the pinion gear look like and other parts up close if you can? Any more evidence of trouble from the missing bits off of that?


Speaking maybe just for myself but the few (not very many) differentials of the sort that failed one was bent - housing but no sounds but had backed into something a lot harder than it. Another coil spring welded on parts to hold them in place totally rusted out and rest looked like crap as well so both those tossed for whole used units that were identical and fine forever more. Dirt cheap in comparison just time to swap brakes and other things over, change out gear oil any gaskets and seals as called for plus the junkyard would take the wrecked one back just for the scrap metal of it - handy all around.


What is your situation for a whole used unit and place(s) that are dependable enough to only take out ones that are a good risk?


If you really can't find a all the parts new for this one I'd be lost. I really don't know of a place near me that would make those or they've been hiding for a lot of years!


There about has to be some identifying marks or #s on the unit and you might find thru the junkyards the whole thing fits lots of different makes or types of similar vehicles by name brand of yours?


Just maybe some help from Daihatsu with the VIN# for whole vehicle would be a good lead to all new stuff. Can't know from here that easily.


Who really made this vehicle in that model year? Does Daihatsu make whole vehicles or buy drivetrains from another sometimes or often?


Been ages, sorry, aren't there two idle gears involved also that use the same larger ring gear? If they don't all match up or another is damaged just this one probably won't last if you did find it,


T



greystroke
New User

Mar 5, 2015, 4:06 PM

Post #8 of 9 (1876 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

The rest of the diff looks great inside, no marks/pitting on the pinion or spider gears, bearings are fine as well. I've now discovered that when my mechanic replaced the pinion oil seal, there is a chance he didn't preload the pinion properly which could have led to the damage. I've managed to source another whole rear diff for $400, there was a lead time of 6-8 months to have a gear cut (at a cost of only $800)! At least I'll have some spare parts if anything else does go wrong (fingers crossed it doesn't though!).

I considered a rear diff swap for a toyota hilux as parts are very similar after the amalgamation of Daihatsu and Toyota but it's about the same price as above so I figured I might as well get the original parts.

Daihatsu stopped making parts for the Feroza back in 2000, and stopped sale of the vehicle in 2010. Contacted Daihatsu directly to see if there was a way of getting parts for the car and they don't even they don't even have part numbers for half the car in their database :/

-Edit - And as for finding one of these in a junk yard in Australia, it'd be gone before you know what happened! These cars are very hard to come by here.


(This post was edited by greystroke on Mar 5, 2015, 4:08 PM)


Tom Greenleaf
Ultimate Carjunky / Moderator
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Mar 5, 2015, 4:31 PM

Post #9 of 9 (1873 views)
Re: 1995 Feroza Hard knocking sound when accelerating Sign In

You've done some great legwork and homework on this thing! OK - it's possible just a gear would work. These are very precise parts as you know of hardened steel ground just so within specs you can't see for crap by eye.


General on the metal like this and parts like this. They are so finely machined it's nuts. Not much room for being wrong or pits if you see any they will ding up the others they work with. Cause in this case would possibly be bits of the chunks missing as they are as hard at the rest and could harm the surfaces.


Parts games - hate that. Have you tried any Ebay type places for someone parting out one?


Manufacturer is no help - great. Any clubs for these vehicles? Are (don't know these or the popularity of them as they're not even sold here) but seems you need to hunt down plain old parts. Been there done that with old car restorations but at the time odds and ends were available just pricey for fast and accurate good stuff new or used.


If there's any indication this is a Toyota part I'd bet it was used in several others by them or whole different companies? Chevrolet sold whole cars made by Toyota with just a name tag change and others too.


Seems it's down to just a hunting game - good luck,


T







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