2007 FORD FIESTA Workshop Manual

Automatic TransmissionlTransaxle External
Controls -Vehicles With: 4-Speed Automatic
307-05-1
3 Transmission (AW81-40) 307-05-1 3
REMOVAL AND INSTALLATION
Selector Lever Knob
, > .
Removal
1. Remove the floor console.
2. Disconnect the overdrive (OID) switch
electrical connector (selector lever assembly
shown removed for clarity).
3. Remove the selector lever knob.
Remove the bolt. i
Installation
1. Install the selector lever knob.
Position the knob.
lnstall the bolt.
2. Connect the OID switch electrical connector
(selector lever assembly shown removed for
clarity).
3. Install the floor console.
2006.0 Fiesta 1212006 G294551 en
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Automatic Transmission/Transaxle External
Controls -Vehicles With: 4-Speed Automatic
307-05-1 4 Transmission (AW81-40) 307-05-1 4
DISASSEMBLY AND ASSEMBLY
Selector Lever
Materials Unclip the lamp.
I I Name S~ecification
1 Grease I S-MlC1021-A I
Disassembly
N0TE:Use vice jaw protectors for all work to be
done in the vice.
1. Disconnect the overdrive (OID) switch
electrical connector.
Assembly
1. To assemble, reverse the disassembly
procedure.
Coat all sliding and turning parts with grease.
2. Remove the selector lever knob.
Remove the bolt.
3. Disassemble the selector lever.
Remove the brake shift interlock actuator.
Remove the selector lever bezel.
Unclip the bezel.
2006.0 Fiesta 1212006 G388014en
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Manual TransmissionlTransaxle and Clutch -
General lnformation
SECTION 308-00 Manual Transmission/Transaxle and
Clutch
- General lnformation
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-00-2
Clutch Dimensions
........................................................................\
.................................. 308-00-2
DIAGNOSIS AND TESTING
Manual Transaxle and Clutch ........................................................................\
..................... 308-00-3
Inspection and Verification
................................................................... ......................... 308-00-3
Gear shifting concerns
........................................................................\
........................... 308-00-3
Transaxle noise concerns
........................................................................\
........................... 308-00-3
Oil leakage concerns
........................................................................\
.................................. 308-00-3
GENERAL PROCEDURES
Gearshift Cable Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1 6 51 3 0) 308-00-1 1
( I Clutch System Bleeding ........................................................................\
......... (16 843 0) 308-00-12
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Manual Transmission/Transaxle and Clutch -
General Information
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Description Specificat
I ions I
Manual transmission fluid
I High melting point grease
Super DOT 4 brake fluid
Clutch Dimensions
I Description I Litres 1 '"<
fluid: 10 - 15
mm below the lower edge of the fluid
filler plug
--
2.3
Description
Pedal travel
Worn clutch disc discard thickness*
Clutch disc diameter:
1.25Ll1.4L Duratec-1 6V (Sigma)
Clutch disc diameter:
1.6L Duratec-I 6V (Sigma)
Clutch disc diameter:
2.OL Duratec-HE (M14)
Clutch disc diameter: 1.4U1.6L Duratorq-TDCi (DV) Diesel
Clutch disc diameter:
1.3L Duratec-8V (Rocam)
mm
135k5
7
190
210
220
210 190
* When the discard thickness has been reached, install a new clutch disc.
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Manual Transmission/Transaxle and Clutch -
308-00-3 General Information 308-00-3
DIAGNOSIS AND TESTING
Manual Transaxle and Clutch
lnspection and Verification
General Equipment selected with the engine running and the parking
brake applied, without any concerns, the clutch
2. If the gear@) cannot be selected, REFER to
Symptom Chart.
Ultraviolet
fluid leak detection equipment
1. Verify the customer concern.
Transaxle noise concerns
2. Visually inspect for obvious signs of mechanical is
OK.
damage. 1. Check the engine and transaxle support for
Oil leaks.
Visibly damaged or worn components.
Visual lnspection Chart insufficient gap between the transaxle and the
body.
REFER to:
RoadlRoller Testing (1 00-00 General
Information, Description and Operation).
Mechanical 2. Road test the vehicle.
4. If the cause is not evident, verify the symptom
and REFER to Symptom Chart.
Oil leakage concerns
Loose or missing nuts or bolts.
( I The following checks should be carried out before
repairing or installing a new transaxle. 1.
Check the transaxle fluid level. If necessary,
3. If a noise occurs in various gears at the same
- - drain off any excess fluid.
The inspection and verification of manual transaxle
concerns can be considered in three main areas. 2. Clean the transaxle and the adjacent areas
carefully and road test the vehicle.
engine speed,
check if the noise also occurs in
3. If an obvious cause for an observed or reported the neutral position.
If it does, the noise is not
concern is found, correct the cause (if possible) caused
by the transaxle.
before proceeding to the next step. 4.
REFER to Symptom Chart.
Gear shifting concerns REFER to: RoadlRoller Testing (1 00-00 General
Information, Description and Operation).
1, Check the operation of the clutch: Lay a block 3. U~ing suitable ultraviolet fluid leak detection
of wood approximately
25 mm thick under the equipment, locate
the leak and check whether
clutch pedal and depress the clutch pedal as the leaking fluid
is transaxle fluid, brake fluid
far as the stop. If first or second gear can be (from the hydraulically operated clutch)
or
engine oil.
4. REFER to Symptom Chart.
Symptom Chart
Symptom Possible Sources Action
I
Clutch slippage Clutch master
cylinder.
Clutch slave cylinder.
Clutch pressure plate.
Clutch disc.
Engine or transaxle housing oil
or fluid
leak@).
GO to Pinpoint Test A.
Clutch chatter or shudder Engine and transaxle
mounts. REFER to:
Noise, Vibration and
Harshness (NVH) (1 00-04,
Diagnosis and Testing).
Clutch pressure plate.
Clutch disc.
Flywheel.
--
GO to Pinpoint Test B.
- -
2006.0 Fiesta 1212006 G25629en
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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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