Ford Fiesta: Clutch Controls - 5-Speed Manual Transmission – B5/IB5/6-Speed Manual Transmission – B6 / Clutch Controls. Diagnosis and Testing

Inspection and Verification

NOTICE: If transmission noise is reported, first check the transmission fluid level. The vehicle should not be driven if the transmission fluid level is low. A low transmission fluid level will damage the transmission.

NOTE: Before attempting to repair any concerns, road test the vehicle to determine which system the concern is in.

NOTE: If an observed or reported concern is found, correct the cause before proceeding.

Gear driven units produce a certain level of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Many conditions, such as road and weather, can amplify normal vehicle noise.

The following overview is a guide to diagnose a transmission or clutch concern:

• Verify and document the customer concern.
  • During the customer interview, if a leak was noticed or if a leak is the concern, check the transmission fluid level. The vehicle should not be driven if the transmission fluid level is low.
• Check fluid level and condition.
• Evaluate the clutch hydraulic system.
• Evaluate the clutch.
• Inspect gearshift mechanism.
• Evaluate the transmission.
• Find the cause of the problem and correct it.

Check Fluid Level and Condition

NOTICE: The vehicle should not be driven if the transmission fluid level is low or damage may occur.

NOTICE: Excessive temperatures may break down the transmission lubricant. If there is reason to believe the transmission has been subjected to temperatures exceeding 135°C (275°F) for an extended period (greater than 20 minutes), change the lubricant immediately.

An incorrect transmission fluid level may affect the transmission operation and can result in transmission damage. For transmission draining and filling, refer to
REFER to: Transmission Fluid Level Check (308-03A Manual Transmission - 5-Speed Manual Transmission – B5/IB5, General Procedures).
REFER to: Transmission Fluid Level Check (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, General Procedures).

A low transmission fluid level can result in poor transmission shifting, engagement or damage. It also indicates a leak in the transmission seals or gaskets.

1. Check the transmission fluid condition.
   
   • Allow the transmission fluid to drip onto a white cloth and examine the stain. Check the transmission fluid for contamination or metal particles.
     

Evaluate Clutch Hydraulic System

1. Verify the clutch hydraulic fluid reservoir is filled to the correct level.
   
   • If the clutch hydraulic fluid level is correct, proceed to clutch check.
     
   • If the clutch hydraulic fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks and repair as necessary.
     

Evaluate the Clutch

1. Apply and release the clutch pedal slowly to check pedal binding. Make sure the clutch pedal can be fully applied and is not restricted by the floor mat.
   

1. Measure the clutch reserve. GO to Pinpoint Test A
   

1. With the engine idling and the park brake applied, move the gearshift lever into 4th gear. Increase engine speed to 2,000 rpm and slowly release the clutch pedal.
   
   • If the engine stalls, the clutch is OK.
     
   • If the engine does not stall, the clutch is slipping. Repair as necessary.
     

1. Compare the clutch evaluation results with the following chart. The following list of conditions are typical clutch concerns.
   

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Pinpoint Test(s)

COMPONENT TEST(S)

Clutch Hydraulic System

1. Verify the clutch hydraulic fluid reservoir is filled to the correct level.
   
   1. If the fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks and repair as necessary.
      
   1. If the fluid is at the correct level, proceed to the next step.
      

1. Apply and release the clutch pedal slowly to check for pedal binding. Make sure the clutch pedal can be fully applied and is not restricted by the floor mat. Verify the pedal return spring is present and functions correctly.
   

1. Measure the clutch reserve. GO to Pinpoint Test A
   

1. Set the park brake. With the clutch pedal in the up position and the engine idling, gently move the gearshift lever forward toward reverse gear until gear clash can be heard. Apply the clutch pedal slowly.
   
   1. If the gears cease to clash (full disengage at 25.4 mm (1 in) to 38.1 mm (1.5 in) from the floor), hold the clutch pedal at the point of disengagement and increase engine speed to 4,000 rpm. The clutch should remain disengaged, clutch OK.
      

1. With the engine idling and the clutch pedal applied, move the gearshift lever into 4th gear. Increase the engine speed to 2,000 rpm and slowly release the clutch pedal.
   
   1. If the engine does not stall, clutch is slipping. Repair as necessary,
      REFER to: Clutch Disc and Pressure Plate (308-01A Clutch - 5-Speed Manual Transmission – B5/IB5, Removal and Installation).
      REFER to: Clutch Disc and Pressure Plate (308-01A Clutch - 5-Speed Manual Transmission – B5/IB5, Removal and Installation).
      REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission – B6, Removal and Installation).
   1. If the engine stalls, clutch is OK.