Clutch Controls. Diagnosis and Testing

Inspection and Verification

NOTICE: If a transmission noise is reported, first check the transmission fluid level. Do not drive the vehicle if the transmission fluid level is low. Low transmission fluid level will damage the transmission.

Mechanical drive components produce a certain level of noise. A small amount of noise is acceptable and may be heard at certain speeds or under various driving conditions. Road and weather conditions may increase normal vehicle noise.

The following overview is a guide for diagnosing transmission or clutch concerns:

• Verify and document the customer concern.
  • During the customer interview, if a leak was noticed or if a leak is a concern, check the transmission fluid level. Do not drive the vehicle with a low transmission fluid level.
• Check the fluid level and condition.
• Evaluate the clutch hydraulic system.
• Evaluate the clutch.
• Inspect the shift mechanism.
• Evaluate the transmission.
• Locate the cause of the concern and correct it.

Check the Fluid Level and Condition

NOTICE: Do not drive the vehicle if the transmission fluid level is low or damage may occur.

NOTICE: Excessively high temperature can cause transmission lubricant breakdown. If there is reason to believe the transmission has been exposed to temperatures above 135 °C for an extended period (more than 20 minutes), replace the lubricant immediately.

An incorrect transmission fluid level can affect transmission operation and may cause transmission damage. For fluid draining and filling, refer to
Refer to: Transmission Fluid Level Check (308-03A Manual Transmission - 5-Speed Manual Transmission - B5/IB5, General Procedures).
Refer to: Transmission Fluid Level Check (308-03B Manual Transmission - 6-Speed Manual Transmission - B6, General Procedures).

A low transmission fluid level can cause poor shifting, gear engagement, or damage. It may also indicate a leak at the transmission seals or gaskets.

1. Check the condition of the transmission fluid.
   
   • Drip transmission fluid onto a white cloth and inspect the stain. Check the transmission fluid for contamination or metal particles.

Evaluate the Clutch Hydraulic System

1. Make sure the clutch hydraulic fluid reservoir is filled to the correct level.
   
   • If the clutch hydraulic fluid level is correct, proceed to the clutch evaluation.
   • If the clutch hydraulic fluid level is low, add fluid as necessary. Inspect the clutch hydraulic system for leaks and repair as necessary.

Evaluate the Clutch

1. 1
   Depress and slowly release the clutch pedal to check the pedal binding. Make sure the clutch pedal is fully released and not restricted by the floor mat.
2. 2
   Measure the clutch reserve. GO TO Pinpoint Test A.
3. 3
   With the engine running at idle and the parking brake applied, move the gear shift lever to 4th gear. Increase engine speed to 2000 rpm and slowly release the clutch pedal.
   

   • If the engine stalls, the clutch is operating correctly.

   • If the engine does not stall, the clutch is slipping. Repair as necessary.
4. 4
   Compare the clutch evaluation results with the following charts. The following list shows typical clutch concerns.

Symptom Chart

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Pinpoint Test(s)

COMPONENT TEST(S)

Clutch Hydraulic System

1. 1
   Make sure the clutch hydraulic fluid reservoir is filled to the correct level.
   

   1. If the fluid level is low, top up the fluid as necessary. Inspect the clutch hydraulic system for leaks and repair as necessary.

   2. If the fluid is at the correct level, proceed to the next step.
2. 2
   Press and slowly release the clutch pedal to check the pedal attachment. Make sure the clutch pedal fully depresses and is not restricted by the floor mat. Make sure the clutch pedal return spring is present and working correctly.
3. 3
   Measure the clutch reserve. GO TO Pinpoint Test A.
4. 4
   Apply the parking brake. With the clutch pedal in the up position and the engine idling, slowly move the gearshift lever forward toward reverse until a gear clash is heard. Slowly release the clutch pedal.
   

   1. If the gear noise stops (full disengagement at 1 in (25.4 mm) to 1.5 in (38.1 mm) from the floor), hold the clutch pedal at the disengagement point and increase engine speed to 4000 rpm. The clutch should remain disengaged; the clutch is good.
5. 5
   With the engine idling and the clutch pedal depressed, move the gearshift lever into 4th gear. Increase engine speed to 2000 rpm and slowly release the clutch pedal.
   

   1. If the engine does not stall, the clutch is slipping. Repair as necessary.
      REFER TO: Clutch Disc and Pressure Plate (308-01A Clutch - 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
      REFER TO: Clutch Disc and Pressure Plate (308-01A Clutch - 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
      REFER TO: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).

   2. If the engine stalls, the clutch is operating correctly.