Ford Fiesta Manuals

Ford Fiesta: Manual Transmission - 6-Speed Manual Transmission – B6 / Manual Transmission. Diagnosis and Testing

Ford Fiesta 2014 - 2019 Service Manual / Manual Transmission, Clutch, Transfer Case and Power Transfer Unit / Manual Transmission - 6-Speed Manual Transmission – B6 / Manual Transmission. Diagnosis and Testing

Inspection and Verification

NOTICE: If transmission noise is reported, check the fluid level first. Do not drive the vehicle if the fluid level is low or damage can occur.

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

  Visual Inspection Chart


Mechanical
  • Oil leaks.
  • Visibly damaged or worn components.
  • Loose or missing nuts or bolts.
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not evident, verify the symptom and REFER to the Symptom Chart.

The following checks should be carried out before repairing or installing a new transmission.

The inspection and verification of manual transmission concerns can be considered in three main areas.

Gear Shifting Concerns

  • Check the operation of the clutch: Lay a block of wood approximately 25 mm thick under the clutch pedal and depress the clutch pedal as far as the stop. If first or second gear can be selected with the engine running and the parking brake applied, without any concerns, the clutch is OK.
  • Clutch does not operate correctly.
  • External gearshift mechanism.
    REFER to: External Controls (308-06 Manual Transmission External Controls - 6-Speed Manual Transmission - B6) .
  • REFER to the Symptom Chart.

Transmission Noise Concerns

  • Check the engine and transmission mountings for sufficient clearance to the transmission and the body.
  • If a noise occurs in various gears at the same engine speed, check if the noise also occurs in the neutral position. If it does, the noise is not caused by the transmission.
  • Road test the vehicle.
  • REFER to the Symptom Chart.

Fluid Leakage Concerns

  • Check the transmission fluid level. If necessary, drain off any excess fluid.
  • Using suitable ultraviolet fluid leak detection equipment, locate the leak and check whether the leaking fluid is transmission fluid, brake fluid (from the hydraulically operated clutch) or engine oil.
  • Clean the transmission and the adjacent areas carefully before road testing.
  • REFER to the Symptom Chart.

Symptom Chart – Transmission Operation

Symptom Possible Sources Action
  • Gears clash when shifting from one forward gear to another
  • Gear teeth/synchronizer damaged
  • INSPECT and REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Transmission jumps out of gear
  • Bolts retaining transmission to engine loose
  • Preload incorrect
  • Internal components damaged
  • Gear teeth worn/damaged
  • TIGHTEN the bolts to specification.
    REFER to: Transmission (308-03C) .
  • CHECK preload. INSPECT the synchronizer for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surface. CHECK the countershaft cluster gear for excessive end play. INSPECT the shift forks for wear. CHECK for loose shift forks on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear and damage. REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Transmission will not shift into one gear — all others OK
  • Internal components
  • For the gear in question, INSPECT the shift rail and fork, the synchronizer, and the gear clutch teeth for restricted travel. REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Transmission is locked in one gear and will not shift out of that gear
  • Internal components
  • INSPECT the gears, the shift rails, the forks and the synchronizer for wear or damage. REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Fluid leaks
  • Transmission fluid
  • Other components leaking
  • Halfshaft seals
  • Input shaft seal
  • Fill and drain plugs
  • CHECK the transmission fluid level and type.
  • REMOVE all traces of fluid on exposed transmission surfaces. CHECK the vent for free breathing. OPERATE the transmission and INSPECT for new leakage. IDENTIFY the leaking fluid as engine, power steering or transmission fluid. REPAIR as necessary.
  • INSPECT and INSTALL new seals as necessary.
    REFER to: Halfshaft Seal LH (308-03C) .
    REFER to: Halfshaft Seal RH (308-03C) .
  • INSPECT, and REPAIR as necessary.
    REFER to: Input Shaft Seal (308-03C) .
  • INSPECT the plug, O-ring, and the threads in the case. REPAIR as necessary. TIGHTEN the plug to specification.
    REFER to: Transmission Fluid Level Check (308-03C) .
  • Significant effort required when downshifting
  • Gear synchronization is inadequate. Gear teeth/synchronizer damaged
  • INSPECT the transmission. INSTALL a new synchronizer assembly with synchronizer rings. INSTALL two new gears belonging to the synchronizer assembly.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Stiff gearshift
  • Transmission fluid
  • Damaged synchronizer rings or inner selector mechanism
  • CHECK that the transmission is filled with the specified transmission fluid and, if necessary, FILL and ADD transmission fluid as necessary.
  • CHECK the internal components for wear or damage, REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • One of the gears cannot be selected
  • Fault between the gearshift lever and gearshift lever housing
  • INSPECT the gearshift lever.
    REFER to: External Controls (308-06E) .
  • Reverse gear cannot be selected
  • Gearshift lever
  • Internal components
  • CHECK the gearshift lever for damage. REPAIR as necessary, remove the gearshift lever to see whether reverse gear can be selected.
  • CHECK the reverse idler gear and the appropriate selector fork, shift rail and synchronizer unit. REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Grinding or clashing noises when shifting into 3rd gear
  • Deflected lubrication condition causing early 3rd gear wear
  • INSTALL a new 3rd gear, 3rd/4th gear shift fork, outer synchronizer ring, inner synchronizer ring, 3rd gear synchronizer cone, 3rd/4th gear synchronizer assembly.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).

Symptom Chart - Transmission NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, Refer to: Noise, Vibration and Harshness (NVH) Section 100-04. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the system for the symptom, Refer to: Noise, Vibration and Harshness (NVH) Section 100-04.

Symptom Possible Sources Action
  • Noisy in forward gears — noise described as rattle or a knock
  • Transmission fluid level low/incorrect type
  • Components grounding out on transmission
  • Bearings/gears worn/damaged
  • Bolts retaining transmission to engine loose
  • ADD or REFILL with the specified transmission fluid.
    REFER to: Transmission Fluid Level Check (308-03C) .
  • CHECK for screws and bolts of chassis components grounding out. REPAIR as necessary.
  • INSPECT the bearings, the gears, and the gear teeth for wear and damage. REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • VERIFY the bolts are tightened to specification.
    REFER to: Transmission (308-03C) .
  • Noise in NEUTRAL occurs after hot soak or under load
  • Neutral rollover noise
  • Transmission
  • A slight rollover gear noise is an acceptable condition. INSTALL a new clutch disc.
    REFER to: Clutch Disc and Pressure Plate (308-01E) .
  • INSPECT and REPAIR as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Slight buzzing, rattling or metallic scraping noise from the transmission at 2,500 to 3,500 rpm when coasting or driving without load (particularly in 2nd and 3rd gear)
  • Rotational vibration from the engine not sufficiently damped by the clutch
  • These noises do not affect the operation and durability of the transmission.
  • Brief scratching noise during gear shifting
  • Inadequate gear synchronization
  • INSPECT the transmission for wear or damage. REPAIR as necessary. INSTALL a complete synchronizer assembly with synchronizer rings. INSTALL two new gears belonging to the synchronizer assembly.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Gear growl — to occur, lug the engine in 1st or 2nd gears, press the throttle to floor and the noise will be heard
  • Reduced preload on the input shaft
  • Acceptable noise under these conditions.
  • Gear whistle — occurs in 2nd, 3rd and 4th gear by pressing the throttle to the floor and letting the vehicle accelerate, hard acceleration to WOT , a very light whistle noise can be heard
  • Driven gears on the output shaft
  • Acceptable noise under these conditions.
  • Clicking noises in reverse gear
  • Reverse gear
  • INSPECT the gears for wear or damage. INSTALL new gears as necessary.
    REFER to: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Disassembly).
  • Clicking, rattling, or rubbing noise in Neutral with clutch pedal released; vehicle not moving
  • Normal gear rollover noise
  • Gear rollover noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Gear rollover noise, inherent in manual transmissions, is caused by the constant mesh of gears turning at the engine idle speed while the clutch is engaged and the transmission is in NEUTRAL.

Pinpoint Tests


PINPOINT TEST G: EXCESSIVE NOISE
G1 CHECK THE TRANSMISSION AT IDLE (A)
  • Start the engine.
  • Press the clutch pedal fully.

Is the noise apparent when the clutch is operated?
Yes GO to G2
No There is a problem with the transmission.
REFER to: Manual Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission – B6, Diagnosis and Testing).
.

G2 CHECK THE TRANSMISSION AT IDLE (B)
  • Run the engine at idle.

Are the noises coming from the pedal box?
Yes CHECK the clutch pedal and bushings.
No GO to G3
REFER to: Clutch Controls (308-02 Clutch Controls - 6-Speed Manual Transmission - B6) .

G3 CHECK THE CLUTCH RELEASE BEARING
  • Remove the clutch slave cylinder/release bearing assembly.
    REFER to: Clutch Slave Cylinder - 5-Speed Manual Transmission – B5/IB5 (308-02 Clutch Controls - 5-Speed Manual Transmission – B5/IB5/6-Speed Manual Transmission – B6, Removal and Installation).
  • Check the release bearing for wear and corrosion.

Are there signs of wear or corrosion?
Yes INSTALL a new clutch release bearing.
REFER to: Clutch Slave Cylinder - 5-Speed Manual Transmission – B5/IB5 (308-02 Clutch Controls - 5-Speed Manual Transmission – B5/IB5/6-Speed Manual Transmission – B6, Removal and Installation).
No CHECK the crankshaft for excessive end float.


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