[ParadoxalShadowPL]

Hello. My first topic so I hope that I do everything ok.

I am the owner of 2011 Hyundai i30 CW with 1.4 liter petrol engine with manual transmission.

From very beginning I have a problem with very strange noise of the gearbox when it is in neutral position.

Here is a video I took last summer: SDC17230prz - YouTube

The clutch is not pressed then. If I only press the clutch the noise is disappearing. Then, when clutch pedal is released the noise is again very loud. That means that when the power from the engine is moved to the gearbox the noise is present. All the time gearbox is in neutral position.

After several visits in different Hyundai services and dealers some of them decided to replace all bearings in the gearbox and fill it with new oil. It helped a bit. Before that, the noise were present all the time when gearbox was in neutral position. After replacement of bearings and oil the noise was only present sometimes, mainly when in neutral position I  speed up the engine to about 2500-3000 RPM. But when I release gas pedal noise was disappearing. I accpeted this situation because I had no more time and nerves to fight with another service and dealer.

But now whole problem is coming back to my i30. I started to hear same loud noise if I only release clutch when gearbox is in neutral position. 

My i30 has now just 2 years and 15600 km of mileage.

I am looking for somebody who had same problem and founded how to solve it.

Sorry if I doubled the topic and if so please redirect me to it.

Hope to get any advices from you all. Please check my video so you have better idea about whole situation.

Regards

[Dazzler]

  Sounds like the thrust or throw-out bearing (think it is known by both names)

Should be fixed under warranty in a 3 year old car I would have thought, but why didn'yt you just take it back to dealer when you first heard it ??

[Shambles]

That doesn't sound right at all

I'm going to stick my neck out here and say you have a clutch plate or thrust bearing problem. You really need to get an independent analysis of this, probably at a clutch specialist.

Welcome to the forum


EDIT: Ninja'd by the Dazzling One

[Dazzler]

The fact that you have had work done on it already should cover you as far as warranty goes (thanks for the extra info you appear to have added later) 

[eye30]

Clutch release bearing would be my guess.

Did the many dealers you visited not mention this as it is usually the first port of call with clutch/gearbox noises

[Dazzler]

Gee, that bearing has lots of names! 

[Keith]

I'd agree with the diagnosis and I agree with the name given by eye30

Clutch release bearing as it's known here in the UK.

[ParadoxalShadowPL]

Thanks for your replies.

I took the car to the dealer as soon as I heard this noise. The car had then about 1500km of  mileage! Dealer tried to convince me that there is nothing to worry about as car is new and needs time to "fit in" (sorry for not perfect english).

I pushed him though, and firstly they replaced full clutch system with clutch release bearing as well. It didnt helped! Same noise as before was heard just after replacing clutch with the release bearing!

Then I decided to change service. They have replaced all bearings inside gearbox and fill it with new oil and again replaced full clutch system with clutch release bearing. It helped for a while.

So i had clutch system replaced twice already!

But the thing is that this noise can only be heard when clutch pedal is released. So the clutch release bearing is not working then, aren't I right? The clutch release bearing is working when clutch pedal is pressed. But then there isnt any noise, everything is allright! So I think that the problem is with something inside the gearbox or low quality oil inside.

The car is produced in 2011, but i bought it at the beginning of 2012 with 5 year warranty. So i still have 3 years of warranty but I am very angry that nobody can solve this problem! I tried with 3 different Hyundai services with the same results. That is the biggest problem.

[Dazzler]

Yes, very frustrating and unusual! Have you contacted Hyundai head office direct by email?

Hopefully you have a record of dates etc.. when work carried out and by whom.

I would send all details to Hyundai and demand a permanent fix (and a loan car as well) 

[Asterix]

Hi ParadoxalShadowPL

 

That doesn't sound right at all.

Back to the dealer and have them confirm this is not right.  If they're not able to find the fault themselves then stand firm and insist they get help from Hyundai headquarter technician.

[ParadoxalShadowPL]

I am in contact with another service. Fortunately in my are there are 4 or 5 different services. I tried to contact with HQ in Poland but with no result. Maybe you have any e-mail addresses for european central customer service or even Korean HQ?

It is a pity that in my country customer service is on such low level. On the other hand I think that if I describe this matter to my frined who is a professional mechanic running his own business he would solve my problem in 2 days. But I cant as warranty would be limited then. Or maybe I should do it and then send an invoice to the Hyundai HQ?

Going back to clutch release bearing - it was replaced twice together with other clutch elements. Last time when the mileage was about 7000 km. So on current clutch system i made about 8500 km. Is it possible that it has broken down again after such small mileage? I am not sport driver. I driver carefully and rather not fast.

So still my guess is bearing inside gearbox or oil.

P.S. Welcome and sorry not to say it at first place!

[Asterix]

Thanks for your replies.

I took the car to the dealer as soon as I heard this noise. The car had then about 1500km of  mileage! Dealer tried to convince me that there is nothing to worry about as car is new and needs time to "fit in" (sorry for not perfect english).

I pushed him though, and firstly they replaced full clutch system with clutch release bearing as well. It didnt helped! Same noise as before was heard just after replacing clutch with the release bearing!

Then I decided to change service. They have replaced all bearings inside gearbox and fill it with new oil and again replaced full clutch system with clutch release bearing. It helped for a while.

So i had clutch system replaced twice already!

But the thing is that this noise can only be heard when clutch pedal is released. So the clutch release bearing is not working then, aren't I right? The clutch release bearing is working when clutch pedal is pressed. But then there isnt any noise, everything is allright! So I think that the problem is with something inside the gearbox or low quality oil inside.

The car is produced in 2011, but i bought it at the beginning of 2012 with 5 year warranty. So i still have 3 years of warranty but I am very angry that nobody can solve this problem! I tried with 3 different Hyundai services with the same results. That is the biggest problem.

Ok. As Dazz says, contact Hyundai headquarter. I would suggest they replace the complete gearbox. Doinng that, they should be able to find out right away if it is the right cure. If not they can remove the complete gearbox from your car and fit the old one again.

[ParadoxalShadowPL]

Another matter is that this noise is not present each time when gearbox is in neutral position. There are days, when it can be heard very loud. And then for week or two in the same situation there isn't any noise. Thats very strange.
Also, when in neutral position of gearbox everything is ok, I just need to push gas pedal for few seconds so the engine can reach 2500-3000 rpm and release it and noise as on the video is heard for 3-4 seconds. And again there are days when in such situation everything is ok.
If clutch release bearing was broken down shouldnt it be heard all time? And shouldnt it be heard when I push clutch pedal and the bearing is contacting with disc spring?
Thank you for your all answers.

[eye30]

If your friend is happy to look and suggest a diagnosis but not to tamper or remove any parts give it a go.

He may be able to give you a few pointers which you can compare to the dealers prognosis

[Phil №❶]

As the clutch "Thrust Bearing"  has been replaced, I don't think that's your problem. I suspect the clutch plate itself, which is made up of several components, including springs to dampen the mechanical effect of the clutch system. The sound is like a partial contact of 2 metal parts. I would request that the transmission be removed and particular attention placed on the clutch plate & flywheel housing and the thrust lever . I think your problem is there, not in the gearbox. For such a low amount of travel, the gearbox would have to be seriously defective and corrected by the work already performed.

[eye30]

Is it possible that the clutch and release bearing have NOT been replaced

[Surferdude]

Is it possible that the clutch and release bearing have NOT been replaced

That's a real possibilty.

[Just Rick]

Is it possible that the clutch and release bearing have NOT been replaced

That's a real possibilty.

Yes experience has told me SOME Hyundai dealers are very good at saying they have done something and in fact they HAVE NOT

[eye30]

With warranty work they may not provide an invoice detailing parts.

However, the work and parts used should be entered on the central database. 

Hy hq should have record of what actual parts etc have been replaced.

May be worth requesting details.

[ParadoxalShadowPL]

Hi. In my warranty book I have two entries confirming that two different dealers have replaced full clutch system in my car. It was replaced twice or.. it wasn't. I have no other option but to believe these entries as I have no possibility to check if the parts were really replaced. Anyways, each time I got my car from the dealers after replacing clutch system I felt little difference when oprating the clutch. So i can believe that it was replaced. Twice. But it didn't affect this strange noise anyhow..

I contacted with some guy from Prague, who had same problem as I have. Here is his YT movie:

Hyundai i30 2012 Strange Transmission Noise - YouTube

He says that after some time dealer decided to replace transmission to completely new one and the problem and noise was gone.

Please correct me and my english if I'm wrong: transmission=gearbox?

What is also very interesting - when the sound/noise is present and I push gear selector a little bit to front (3rd gear position) the noise is decreasing. When I push it a little bit back (towards 4th gear position) the noise is increasing. I'm pushing selector without using clutch, just by 1 or 2 mm towards 3rd or 4th gear position and it affect on noise level. So maybe the thing is about bad calibration of gear selector. i dont know. So many ideas and still not satisfying answer and problem solution..

I will have to find time to visit another dealer or two. I still have 3 years of warranty but it is just frustrating for me to take day off from work just to visit Hyundai dealer and hear that they don't know how to help or that everythins is ok and they dont hear anything suspicious. 

Regards

[Phil №❶]

Be sure to mention the gear stick effect to the dealer, sometimes the owner leads the dealer to the problem.

Transmission is gearbox, yes. 

[Dazzler]

It is very frustrating. If you go to the Global or Korean Hyundai website there should be a link to contact them. If you can't find one we will try and help you!

 Yes transmission = gearbox

[Shambles]

Hmmm... something is starting to smell of "lay shaft"

[Asterix]

Hmmm... something is starting to smell of "lay shaft"

 

[eye30]

Question i would like to ask is.....

Why did 2nd dealer do the same work as the first as hy hq would not give warranty authority to do the same job again on the one car without it being checked by their own engineers

[ParadoxalShadowPL]

Question i would like to ask is.....

Why did 2nd dealer do the same work as the first as hy hq would not give warranty authority to do the same job again on the one car without it being checked by their own engineers

I just don't know.

Just called another dealer. They said that if I come to them and the noise will be hearable they will disassemble the gearbox and check all bearings and things inside. But if the noise won't be present they will do nothing. It's hard for me to make the gearbox noisy just when Im at dealers place. The noise is just sometimse hearable very loud and sometimes gearbox is super silent. I think I will make new record of the noise and take it on the CD with me when I go there. And instead of having gearbox fixed again I want new one to be put into my car. Last year they fixed the bearings and it was better but not perfect but now all problems are coming back I feel and hear.

What about that lay shaft??

[ParadoxalShadowPL]

Hi everyone.

I have some news about problem with my car.

Three weeks ago I wrote to the importer (Hyundai Motor Poland) with complaint. They contacted service from my area with me, so I drove there and leave the car for inspection. Last week I've received information that importer agreed to replace complete gearbox + complete clutch system +flywheel in my car. So, I will have whole system new

Now service is waiting for parts delivery and it will take next 2 or 3 weeks to deal with everything.

Then I hope probelm will be gone.

Bad thing is that they have no idea what can cause this strange noise but I don't care if only replacement of gearbox, clutch and flywheel will help.

[Asterix]

That's good news. 

I hope Hyundai will inspect the part from your car to learn...

[Phil №❶]

That is great service from Hy in Poland and your dealer. Hope that fixes your problem.

[eye30]

Result!