2007 FORD FIESTA transmission oil

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 -
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 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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308-02-6 Clutch Controls 308-02-6
REMOVAL AND INSTALLATION
Clutch Slave Cylinder(l6 862 4) /'
Materials Alf brake fluid is spilt on the paintwork, the
Name Specification affected
area must be
immediately washed
ESDM-1 C220-A down with cold water. High-temperature
grease
ADO not apply grease on any area of the
clutch slave cylinder.
Removal Install the clutch slave cylinder.
I. Remove the transaxle. For additional
information, refer to: (308-03 Manual
TransmissionlTransaxle)
Transaxle - 1.2 5L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (Removal),
Transaxle - 1.3L Duratec-8V (Rocam)
(Re m ova I),
Transaxle - 2.OL Duratec-HE (M14) (Removal),
Transaxle - 1.4L Duratorq-TDCi (DV)
Dieselll.6L Duratorq-TDCi (DV) Diesel
(Removal).
2. Clean any grease and foreign material from
the input shaft.
3. CAUTIONS:
Alf brake fluid is spilt on the paintwork, the
affected area must be
immediately washed
down with
cold water.
Ausing suitable adhesive tape, cover the
input shaft
splines to prevent damage to the
input shaft
oil seal.
Remove the clutch slave cylinder.
Installation
1. CAUTIONS: 2.
Remove the adhesive tape from the input
shaft
splines.
3. Coat the input shaft splines with a thin layer
of high-temperature grease.
4.
Install the transaxle. For additional
information, refer to: (308-03 Manual
TransmissionlTransaxle)
Transaxle - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (Installation),
Transaxle - 1.3L Duratec-8V (Rocam)
(Installation),
Transaxle - 2.OL Duratec-HE (M14)
(Installation),
Transaxle - 1.4L Duratorq-TDCi (DV)
Dieselll.6L Duratorq-TDCi (DV) Diesel
(Installation).
2006.0 Fiesta 1212006 GI1 3288en
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308-03-5 Manual Transmission/Transaxle 308-0315
DESCRIPTION AND OPERATION
Manual Transaxle
i
General
The iB5 manual transmission is a two shaft 1st and 2nd gears are double synchronised.
transmission. There is no need to change the oil.
All gear wheels are helical toothed, synchronised
(except reverse gear) and run in plain bearings.

2006.0 Fiesta 1212006 G281365en
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308-03-26 Manual Transmission/Transaxle 308-03-26
REMOVAL
Remove the heat shield. 3. Remove the center bearing cap.
19. CAUTIONS: 21. CAUTIONS:
Asupport the halfshaft. The inner joint A~upport the halfshaft. The inner joint
must not be bent more than
18 degrees.
must not be bent more than 18 degrees.
The outer joint must not be bent more than
The outer joint must not be bent more than
45 degrees. 45 degrees.
ADO not damage the halfshaft oil seal. ADO not damage the halfshaft oil seal.
N0TE:Plug the transaxle to prevent oil loss or dirt N0TE:PIug the transaxle to prevent oil loss or dirt
ingress. ingress.
Using the special tool, detach the left-hand
Detach the halfshaft and the intermediate
halfshaft from the transaxle and secure
it to
shaft from the transaxle and secure it to one
one side. side.
Discard the snap ring. Allow the oil to drain into a suitable container.
Allow the oil to drain into a suitable container.
22. Lower the vehicle.
20. N0TE:Discard the intermediate shaft center
bearing cap and locknuts.
Remove the intermediate shaft center
bearing cap.
1. Remove the locknuts.
2. Detach the heat shield.
-- -
2006.0 Fiesta 1212006 GI I 3290en
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