2007 FORD FIESTA transmission fluid

Manual Transmission/Transaxle and Clutch -
308-0014 General Information 308-00-4
DIAGNOSIS AND TESTING
Symptom
Possible Sources Action
Insufficient brake fluid. FILL the brake master cylinder
reservoir to the MAX mark.
INSPECT the brake and clutch
hydraulic systems for leaks.
REPAIR as necessary. I
Air in the clutch hydraulic
system.
Clutch pedal free travel.
Clutch pressure plate.
Clutch disc.
Crankshaft end play.
Clutch pressure plate.
Clutch disc.
Crankshaft end play.
Clutch drag.
BLEED the system.
REFER to: Clutch System
Bleeding (308-00 Manual
Transmission/Transaxle and
Clutch
- General Information,
General Procedures).
GO to Pinpoint Test C.
INSTALL a new clutch disc and
pressure plate.
REFER to: Clutch Disc and
Pressure Plate (308-01
Clutch, Removal and Installa-
tion).
CHECK the crankshaft end
play.
REFER to: Crankshaft End
Play (303-00 Engine System
- General Information,
General Procedures).
GO to Pinpoint Test C.
Gearshift cable adjustment CHECK the gearshift cable
adjustment.
REFER to: Gearshift Cable
Adjustment (308-00 Manual
Transmission/Transaxle and
Clutch
- General Information,
General Procedures).
External controls. CHECK the external controls
for wear or damage. INSTALL
new components as necessary.
Gear wheels. DISASSEMBLE the transaxle. I
REFER to: Transaxle (308-03
Manual Transmis-
sion/Transaxle, Disas-
sem bly).
INSTALL new components as
necessary.
2006.0 Fiesta 1212006 G25629en
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Manual Transmission/Transaxle and Clutch -
308-00-5 General Information 308-00-5
DIAGNOSIS AND TESTING
Symptom
Excessive noise Possible Sources
Action
Selector mechanism.
DISASSEMBLE the transaxle.
REFER to: Transaxle (308-03 Manual Transmis-
sionITransaxle, Disas-
sem bly).
INSTALL new components as
necessary.
DISASSEMBLE the transaxle.
REFER to: Transaxle (308-03 Manual Transmis-
sionITransaxle, Disas-
sem bly).
INSTALL new components as
necessary.
Engine vibrations inadequately
damped.
REFER to: Noise, Vibration and
Harshness (NVH) (1 00-04,
Diagnosis and Testing).
Transaxle fluid level low. CHECK the transaxle for leaks.
I TOP UP the transmission fluid.
Engine or transaxle is in
contact with the chassis or
body. REFER
to:
PowertrainIDriv-
etrain Mount Neutralizing
(1 00-04 Noise, Vibration and
Harshness, General Proced-
u res)
.
Engine and transaxle out of
alignment. REFER
to: PowertrainIDriv-
etrain Mount Neutralizing
(I 00-04 Noise, Vibration and
Harshness, General Proced-
u res)
.
External controls. CHECK the external controls
for wear or damage. INSTALL
new components as necessary.
Gear wheels and bearings.
DISASSEMBLE the transaxle.
REFER to: Transaxle (308-03
Manual Transmis-
sion/-rransaxle, Disas-
sem bly).
INSTALL new components as
necessary.
Clutch pedal. I GO to Pinpoint Test D.
Clutch release bearing.
Fluid leakage Clutch master cylinder.
Clutch slave cylinder.
Clutch hydraulic lines.
INSPECT the brake and clutch
hydraulic systems for leaks.
REPAIR as necessary.
2006.0 Fiesta 1212006 G25629en
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Manual Transmission/Transaxle and Clutch -
308-00-6 General Information 308-00-6
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
Halfshaft seal. INSTALL
a new halfshaft seal.
REFER to: (308-03 Manual
Transmission/Transaxle)
Halfshaft Seal LH (In-vehicle
Repair),
Halfshaft Seal RH (In-vehicle
Repair).
Fluid leak between the
transaxle housing sections. DISASSEMBLE the transaxle
and clean the mating faces.
CHECK the mating faces for
damage. SEAL the transaxle
with sealant.
REFER to: Transaxle (308-03
Manual Transmis-
sion/-rransaxle, Assembly).
PINPOINT TEST A
: CLUTCH SLIPPAGE
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS
Al: TEST CLUTCH SLIPPAGE
Lock the wheels and apply the parking brake.
Start the engine and engage fourth gear.
Run the engine at approximately 2000 rpm.
Release the clutch pedal slowly.
Does the engine stall when the clutch pedal is
fully released?
+ Yes Clutch OK.
+ No
GO to
A2.
A2: CHECK THE CLUTCH PEDAL OPERATION
Depress clutch pedal and allow it to return.
Does the pedal return to the initial position?
+ Yes
GO to A3.
-, No
GO to A4.
2006.0 Fiesta 1212006 G25629en
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Manual TransmissionlTransaxle and Clutch -
308-00-7 General Information 308-00-7
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAl LSIRESU LTSIACTIONS
PINPOINT TEST
B : CLUTCH CHATTER OR SHUDDER
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS

B1: TEST FOR CLUTCH SHUDDER
Start the engine.
Engage the clutch and select fourth gear.
Run the engine at approximately 2000 rpm.
A3: CHECK THE CLUTCH DISC AND PRESSURE PLATE
rn Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate
(308-
01 Clutch, Removal and lnstallation).
Is the clutch disc or pressure plate contamin-
ated with oil or hydraulic fluid?
-+ Yes
CHECK the engine and transaxle for leaks.
INSTALL new components as necessary.
TEST the system for normal operation.
-+ No
INSTALL a new clutch disc and pressure
plate.
REFER to: Clutch Disc and Pressure Plate
(308-01 Clutch, Removal and lnstallation).
TEST the system for normal operation.
A4: CHECK THE CLUTCH HYDRAULIC SYSTEM
rn Release the clutch slave cylinder bleed nipple.
Does the pedal return to the initial position?
--+ Yes
INSTALL a new clutch slave cylinder.
REFER to: Clutch Slave Cylinder (308-02
Clutch Controls, Removal and Installation).
TEST the system for normal operation.
--+ No
INSTALL a new clutch master cylinder.
REFER to: Clutch Master Cylinder (308-02
Clutch Controls, Removal and lnstallation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G25629en
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Manual Transmission/Transaxle and Clutch -
General Information
DIAGNOSIS AND TESTING
TEST CONDITIONS
Release the clutch pedal slowly.
Does the clutch take up the drive smoothly?
-+ Yes
Clutch is OK.
-+ No
GO to
B2.
B2: CHECK THE CLUTCH DlSC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
rn Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-
01 Clutch, Removal and Installation).
Is the clutch disc and pressure plate contamin-
ated with oil or hydraulic fluid?
-+ Yes
CHECK the engine and transaxle for leaks.
INSTALL new components as necessary.
TEST the system for normal operation.
-+ No
GO to B3.
B3: CHECK THE CLUTCH
DlSC AND PRESSURE PLATE
rn Visually check the clutch disc and pressure
plate.
Is the clutch disc and pressure plate worn or
damaged?
-+ Yes INSTALL a new clutch disc and pressure
plate.
REFER to: Clutch Disc and Pressure Plate
(308-01 Clutch, Removal and Installation).
TEST the system for normal operation.
-+ No
CARRY OUT the flywheel clutch surface
inspection.
REFER to: Flywheel Inspection (303-00
Engine System
- General Information,
General Procedures).
TEST the system for normal operation.
2006.0 Fiesta 12/2006 G25629en
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Manual Transmission/Transaxle and Clutch -
General Information
DIAGNOSIS AND TESTING
PINPOINT TEST C : CLUTCH DRAG
TEST CONDITIONS
Cl: CHECK THE OPERATION OF THE CLUTCH PEDAL
rn Bleed the clutch system.
REFER to: Clutch System Bleeding (308-00,
General Procedures).
Does the clutch properly disengage after
bleeding?
-, Yes
Clutch system is OK.
+ No
GO to C2.
C2: CHECK THE CLUTCH DlSC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
rn Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate
(308-
01 Clutch, Removal and Installation).
Is the clutch disc and pressure plate contamin-
ated with oil or hydraulic fluid?
+ Yes
CHECK the engine and transaxle for leaks.
INSTALL new components as necessary.
TEST the system for normal operation.
+ No
GO to C3.
C3: CHECK THE CLUTCH DlSC AND PRESSURE PLATE
Visually check the clutch disc and pressure
plate.
Is the clutch disc and pressure plate worn or
damaged?
-, Yes
INSTALL a new clutch disc and pressure
plate.
REFER to: Clutch Disc and Pressure Plate
(308-01 Clutch, Removal and Installation).
TEST the system for normal operation.
-, No
GO to C4.
2006.0 Fiesta 1212006 G25629en
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Manual Transmission/Transaxle and Clutch -
308-00-1 2 General Information 308-00-1 2
GENERAL PROCEDURES
Clutch System Bleeding(l6 843 0)
Special Tool(s) 6. Fill the reservoir of the special tool with (,, .
I Hand Vacuum approximately 100 ml of new brake fluid.
7. N0TE:Make sure that the special tool
reservoir is positioned lower than the bleed
nipple.
Install the special tool.
Super DOT 4 Brake
1 Fluid
I
Materials
Name Specification
ESD-M6C57-A
A WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
handling. If brake fluid contacts the eyes,
flush the eyes for 15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink
8. Using the special tool, bleed the clutch
water and induce vomiting. Get medical system.
attention immediately. Failure to follow
Pump approximately 80 ml of brake fluid into
these instructions may result in personal the clutch svstem. (
injury. w
9. Close the bleed nipple. A CAUTI0N:Y brake fluid is spilt on the
paintwork, the affected area must be 10.
Remove the special tool.
immediately washed down with cold water.
11. Lower the vehicle, if necessary.
N0TE:lf proprietary brake bleeding equipment is
available, this can be used to bleed the clutch
system, following the method below. The maximum
pressure must not exceed
1.5 bar.
N0TE:The clutch control system is self-venting.
The components are arranged in such a way that
small amounts of air trapped in the system are
removed automatically during clutch operation.
12. In order to remove any small amounts of
trapped air remaining in the system,
operate the clutch pedal several times
(maximum five times), using the full clutch
pedal travel.
13. Check the fluid level in the brake fluid
reservoir and top up to the MAX mark with
brake fluid if necessary.
1. Remove the air cleaner, if necessaryfor 14. Install the battery tray, if necessary.
additional information, refer to
Section
303-12 [Intake Air Distribution and 15.
Install the battery, if necessary. For
Filtering]. additional
information, refer to
Section 414-01 [Battery, Mounting and
2. Remove the battery, if necessary. For
Cablesl.
additional information, refer to
Section
414-01 [Battery, Mounting and . 16. Install the air cleaner, if necessary. For
Cables]. additional
information, refer to
Section 303-1
2 [Intake Air Distribution and - 3. Remove the battery tray, if necessary.
Filtering]. (' L 4. Drain the brake fluid reservoir.
17. Test the clutch control system for normal "I-
5. Raise and support the vehicle, if necessary. operation.
For additional information, refer to
Section 100-02 [Jacking and Lifting].
2006.0 Fiesta 1212006 GI 83752en
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Clutch Controls
DESCRIPTION
AND OPERATION
Because of this separate chamber, the braking
system remains operational if a leak occurs in the
hydraulic clutch system.
Function
Pressure is created in the master cylinder when
the clutch pedal is operated.
The hydraulic fluid in the master cylinder is put
under pressure and fed through the pressure pipe
to the slave cylinder.
The displaced hydraulic fluid moves the piston in
the slave cylinder and this in turn slides the release
bearing axially.
The release bearing pushes the bearing inner ring
against the tongues of the diaphragm spring.
The spring induced grip between the clutch disc
and the flywheel is broken.
When the clutch pedal is released the diaphragm
spring presses the piston in the slave cylinder back
to its starting position. The spring induced grip
between the clutch disc and the flywheel is created
again.
A spring in the slave cylinder ensures preload on
the release bearing.
The release bearing is always touching the
pressure plate because of this preload. The extra
travel caused by clutch lining wear is compensated
for by the preload.
There is a choke assembly in the slave cylinder
which helps to increase smoothness when pulling
away.
Because of the choke assembly, the pressure drop
of the fluid leaving the slave cylinder and returning
to the reservoir is delayed.
Because of this, the clutch closing time is delayed
when the clutch pedal is released suddenly, and
a soft and comfortable clutch engagement is
achieved.
Choking does not occur during clutch
disengagement.
A CAUTI0N:Vehicles with an automated shift
manual (ASM) transmission have
a slave
cylinder without
a choke assembly. The
slave cylinders must not be exchanged for
one another.
N0TE:The clutch pedal travel cannot be adjusted.
The release bearing is an interference fit in the
slave cylinder and cannot be renewed separately.
2006.0 Fiesta 1212006 G281360en
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