Ford Fiesta: Clutch - 6-Speed Manual Transmission – B6 / Clutch. 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.

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:

• 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.

Verify Customer 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.
  • When was it first noticed?
  • Did it appear suddenly or gradually?
  • Did anything unusual occur that would coincide with it or precede it?

• Identify when the condition occurs:
  • Hot or cold vehicle operating conditions?
  • Type of terrain?
  • City/highway driving?
  • Driving at a particular speed, coasting, hard acceleration?
  • Shifting, upshifts, downshifts, in a particular gear, in all gears?
• Has the transmission/clutch been repaired before or components installed?
  • Check the vehicle service record. Note any repairs.

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: 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 - Clutch Operation

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. For information about these practices
REFER to: About this Manual (100-00 General Information, Description and Operation).

Pinpoint Test(s)

COMPONENT TEST(S)

Clutch

1. Slowly press and release the clutch pedal to see if the pedal is binding. Make sure the clutch pedal can be fully pressed and is not restricted by the floor mat. Verify the pedal return spring is present and is functioning correctly.
   

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

1. With the engine idling, the parking brake on and the clutch pedal up, gently move the gearshift lever into a forward or reverse gear, until gear clash can be heard. Slowly press the clutch pedal.
   

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. Any concerns indicate a worn or damaged clutch. Repair as necessary.
   

1. With the engine idling, move the gearshift lever into 4th gear. Increase the engine to 2,000 rpm and slowly release the clutch pedal.
   

1. If the engine stalls, the clutch is OK.
   

1. If the engine does not stall, the clutch is slipping. Repair as necessary.
   

1. Compare the road test results with the symptom chart. The chart is a list of conditions that are typical faults.
   REFER to: Clutch (308-01B Clutch - 6-Speed Manual Transmission – B6, Diagnosis and Testing).