Ford Fiesta Quiz
Manual Transmission, Clutch, Transfer Case and Power Transfer Unit

Clutch. Diagnosis and Testing

In this manual: Manual Transmission, Clutch, Transfer Case and Power Transfer Unit
Service Information — 27Suspension — 48Transmission — 9Brake System — 52Steering — 21Engine — 140Manual Transmission, Clutch, Transfer Case and Power Transfer Unit — 48Exhaust System — 6Fuel System — 21Climate Control System — 58Instrumentation and Warning Systems — 26Battery and Charging System — 20Infotainment Systems — 41Lighting — 29Power Distribution — 11Electronic Function Group — 30Body and Paint — 275Frame and Mounting — 3
13steps
~78min
3/5difficulty
Done 0 of 13

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:

  • 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.

Verify the Customer Concern

  • 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.
    • When was it first noticed?
    • Did it appear suddenly or gradually?
    • Did anything unusual happen that coincided with or preceded the condition?
  • Determine when the condition occurs:
    • Hot or cold vehicle operating conditions?
    • Type of terrain?
    • City or highway driving?
    • Driving at a specific speed, coasting, rapid acceleration?
    • Shifting: upshift, downshift, in a specific gear, in all gears?
  • Was the transmission or clutch previously repaired or were components installed?
    • Check the vehicle service history. Note any repairs.

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 transmission draining and filling,
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.
    • Place a drop of transmission fluid on white paper towel 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. Check the clutch hydraulic system for leaks and repair as necessary.

Evaluate the Clutch

  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. Measure the clutch reserve. GO TO Pinpoint Test A.
  3. With the engine idling and the parking brake applied, move the shift lever into 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. Compare the clutch evaluation results with the following charts. The following list shows typical clutch concerns.

Symptom Chart - Clutch Operation

The diagnostics in this manual assume a certain level of skill and knowledge of Ford-specific diagnostic techniques. For information on these practices
Refer to: About This Manual (100-00 General Information, Description and Operation).

Condition Possible Sources Action
Clutch slipping
  • Clutch pedal reserve
  • Worn or damaged pressure plate
  • Clutch disc facing
  • Glazed or oil-soaked clutch disc surface
  • Flywheel
 GO to Pinpoint Test A
Clutch rattles, clunks or shudders
  • Loose or damaged engine or transmission mounts
  • Oil on clutch disc surface
  • Worn pressure plate
  • Clutch disc facing
  • Loose or damaged flywheel
  • Worn clutch disc
 GO to Pinpoint Test B
Clutch drag
  • Insufficient clutch hydraulic fluid
  • Air in the hydraulic system
  • Clutch pedal reserve
  • Diaphragm spring
  • Clutch Disc
  • Clutch disc splines
  • Oil on clutch disc surface
 GO to Pinpoint Test C
Clutch pedal pulsation
  • Clutch and brake pedal pivot shaft not properly lubricated.
  • Flywheel
  • Worn pressure springs
  • Clutch diaphragm finger runout
 GO to Pinpoint Test B
Vibrations related to the clutch
  • Engine component grounding to frame
  • Accessory drive belt
  • Flywheel attaching bolts loose
  • Flywheel
  • Unbalanced clutch pressure plate
 GO to Pinpoint Test B
Harsh shifting
  • Insufficient clutch hydraulic fluid
  • Clutch pedal reserve
  • Transmission concern
 GO to Pinpoint Test C
Driveline clunk on acceleration
  • Broken dual-mass flywheel
 Accelerate the vehicle in top gear from 1000 rpm to 2000 rpm with the throttle fully open. If the driveline noise is clearly audible during acceleration but stops when the accelerator pedal is released, remove the clutch and inspect the flywheel.
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
Refer to: Flywheel Inspection - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (303-00 Engine System - General Information, General Procedures).
Heavy knock/vibration while driving
  • Broken dual-mass flywheel
 Accelerate the vehicle smoothly between idle and 2000 rpm. If there is excessive rumbling and harsh vibration, remove the clutch and inspect the flywheel.
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
Refer to: Flywheel Inspection - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (303-00 Engine System - General Information, General Procedures).
Knock at idle
  • Broken dual-mass flywheel
 With the engine idling and the transmission in NEUTRAL, slowly depress the clutch pedal. If excessive gear rattle is heard when the clutch is engaged, remove the clutch and inspect the flywheel.
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
Refer to: Flywheel Inspection - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (303-00 Engine System - General Information, General Procedures).
Knock during start-up
  • Broken dual-mass flywheel
 Start the engine with the transmission in NEUTRAL. If excessive gear noise is heard during start-up, remove the clutch and inspect the flywheel.
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
Refer to: Flywheel Inspection - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (303-00 Engine System - General Information, General Procedures).
Rattle on shutdown
  • Broken dual-mass flywheel
 With the engine running and the transmission in NEUTRAL, turn the ignition to the OFF position. If a harsh metallic noise is heard during the last revolutions just before the engine stops, remove the clutch and inspect the flywheel.
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
Refer to: Flywheel Inspection - 1.6 L EcoBoost (132 kW/180 L hp) - Sigma (303-00 Engine System - General Information, General Procedures).

Pinpoint Test(s)


PINPOINT TEST A: CLUTCH SLIPPING
A1 CHECK CLUTCH SLIPPAGE
  • Apply the parking brake.
  • Start the engine and select 4th gear.
  • Run the engine at approximately 2000 rpm.
  • Slowly release the clutch pedal.

Does the engine stall when the clutch pedal is fully released?
Yes Clutch is OK.
No GO to A2
A2 MEASURE CLUTCH PEDAL FREE PLAY
  • Attach a cable tie to the clutch pedal, then attach a tape measure to it.
  • Pull the tape measure to the steering wheel. Route it through the steering wheel opening. Place a piece of masking tape on the steering wheel and an index mark with painter's tape.
  • Fully depress the clutch pedal and start the vehicle.
  • Shift the transmission into REVERSE, then move the shift lever slightly forward to the position between REVERSE and NEUTRAL. Slowly release the clutch pedal (if the vehicle creeps backward, move the shift lever forward slightly more). The transmission will behave as if in NEUTRAL, but the reverse gear synchronizer will be bypassed.
  • With the clutch pedal released, carefully pull the shift lever into the REVERSE position. Gear clash can now be heard.
  • Slowly depress the clutch pedal. Using the mark on the tape as a reference, note the measurement when the gear clash stops or the shift lever moves into the REVERSE position. Depress the clutch pedal to the downstop. The difference between the measurement taken when the gear clash stops and the measurement taken at the downstop is the clutch pedal free play.
    Item Pedal position
    1 Gear clash begins
    2 Gear clash ends
    3 Clutch pedal at downstop

Clutch pedal free play is between 0.0394 in (1 mm) and 0.1181 in (3 mm).
Yes Clutch pedal free play is within specification. VERIFY the customer concern.
No INSTALL a new clutch disc and pressure plate.
Refer to: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
PINPOINT TEST B: CLUTCH CHATTERS, JUDDERS OR DRAGS
B1 CHECK ENGINE OR TRANSMISSION MOUNTS
  • Inspect all engine and transmission mounts for loose fasteners or damage.

Are any engine or transmission mounts loose or damaged?
Yes TIGHTEN or INSTALL new engine or transmission mounts. CHECK the system for normal operation.
No GO to B2
B2 CHECK THE PRESSURE PLATE BOLTS
  • Inspect the pressure plate-to-flywheel bolts.

Is any of the pressure plate-to-flywheel bolts loose?
Yes TIGHTEN or INSTALL new bolts.
REFER TO: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
No GO to B3
B3 CHECK THE PRESSURE PLATE
  • Remove the clutch pressure plate.
  • Inspect the clutch pressure plate for wear or damage.

Is there any evidence of damage to the pressure plate?
Yes INSTALL a new clutch pressure plate.
REFER TO: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
CHECK the system for normal operation.
No GO to B4
B4 CHECK THE CLUTCH DISC
  • NOTE: If the clutch disc internal damper is damaged or contaminated with grease or oil, the noise will sound like "transmission rattle".
  • Inspect the clutch disc for wear or damage.

Is the clutch disc in good condition?
Yes GO to B5
No INSTALL a new clutch disc.
REFER TO: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
CHECK the system for normal operation.
B5 CHECK THE FLYWHEEL
  • Inspect the flywheel for wear or damage.

Is the flywheel in good condition?
Yes GO to B6
No REPAIR or INSTALL a new flywheel, as necessary.
REFER TO: Flywheel (Engine 303-01B - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).
CHECK the system for normal operation.
B6 CHECK THE INPUT SHAFT
  • Inspect the input shaft for evidence of wear, damage or corrosion.

Is there any evidence of wear or corrosion on the input shaft?
Yes If wear or damage is found, INSTALL a new input shaft.
REFER TO: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission - B6, Disassembly).
If corrosion is found on the input shaft splines, apply a small amount of grease to the input shaft splines.
No CONFIRM the customer concern. Refer to Symptom Chart: Transmission
REFER TO: Manual Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission - B6, Diagnosis and Testing).
PINPOINT TEST C: CLUTCH DRAG
C1 CHECK THE CLUTCH FLUID LEVEL
  • Check the clutch fluid level.

Is the clutch fluid level between the MAX and MIN marks on the brake fluid reservoir?
Yes GO to C2
No FILL the reservoir to specification, CHECK the brake and clutch systems for leaks. CHECK the clutch system for normal operation.
C2 CHECK THE CLUTCH PEDAL FREE PLAY
  • Manually depress the clutch pedal fully and release.
  • Measure the pedal travel.

Is the measured dimension between 0.0394 in (1 mm) and 0.3150 in (8 mm)?
Yes GO to C3
No BLEED the clutch hydraulic system.
REFER TO: Clutch Bleeding (308-02 Clutch Actuation - 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
CHECK the clutch pedal free play. If necessary, remove the clutch pedal.
C3 CHECK THE CLUTCH PRESSURE PLATE DIAPHRAGM SPRING.
  • Remove the transmission.
    REFER TO: Transmission (308-03B Manual Transmission - 6-Speed Manual Transmission - B6, Removal).

Does the clutch pressure plate or Belleville clutch pressure plate spring show signs of wear or damage?
Yes INSTALL a new clutch pressure plate.
REFER TO: Clutch Disc and Pressure Plate (308-01B Clutch - 6-Speed Manual Transmission - B6, Removal and Installation).
CHECK the system for normal operation.
No CONFIRM the customer concern.

COMPONENT TEST(S)

Grab

  1. Slowly depress and release the clutch pedal to check for pedal sticking. Make sure the clutch pedal can be fully depressed and is not restricted by the floor mat. Make sure the pedal return spring is present and working correctly.
  2. Measure the clutch reserve. GO TO Pinpoint Test A.
  3. With the engine idling, parking brake applied and clutch pedal depressed, move the gear shift lever smoothly into forward gear or reverse gear until a gear clash is heard. Slowly release the clutch pedal.
  4. 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. Any problems indicate a worn or damaged clutch. Repair as necessary.
  6. With the engine idling, move the gear shift lever into 4th gear. Increase engine speed to 2000 rpm and slowly release the clutch pedal.
  7. If the engine stalls, the clutch is operating correctly.
  8. If the engine does not stall, the clutch is slipping. Repair as necessary.
  9. Compare the road test results with the symptom chart. The chart is a list of conditions that are typical faults.
    REFER TO: Clutch (308-01B Clutch - 6-Speed Manual Transmission - B6, Diagnosis and Testing).

Test yourself

A quick Ford Fiesta quiz: every answer comes with an explanation and a link to the manual page.