Manual Transmission, Clutch, Transfer Case and Power Transfer Unit

External Controls. Diagnosis and Testing

5steps
~30min
2/5difficulty
Done 0 of 5

Operating Principles

Inspection and Verification

  1. Verify the customer concern.
  2. Visually inspect for obvious signs of mechanical damage.
  3. Make sure the gear shift cables are routed correctly and are not stretched or restricted by other components.
  4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  5. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
  • External controls do not operate freely.
  • Gear shift cables incorrectly adjusted.
  • ADJUST the gear shift cables.
    REFER TO: Gear Shift Cables - 1.6 L Duratec-16V Ti-VCT (88 kW/120 L PS) - Sigma, 5-Speed Manual Transmission - B5A/5-Speed Manual Transmission - B5/IB5 (308-06 External Manual Transmission Controls - 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).
    REFER TO: Gear Shift Cables - 6-Speed Manual Transmission - B6 (308-06 External Manual Transmission Controls - 5-Speed Manual Transmission Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).
  • Gear selector lever damaged.
  • Selector mechanism damaged.
  • Gear shift cables damaged.
  • GO to Pinpoint Test A

Pinpoint Tests


DIAGNOSTIC TEST A: EXTERNAL CONTROLS DO NOT OPERATE FREELY
A1 CHECK THE GEAR SELECTOR LEVER
  • Disconnect the gear shift cables from the gear selector lever.

Is the gear selector lever difficult to operate?
Yes Install a new gear selector lever.
REFER TO: Gear Selector Lever (308-06 External Manual Transmission Controls - 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).
No GO to A2
A2 CHECK THE GEAR SHIFT CABLES
  • Connect the gear shift cables to the gear selector lever.
  • Disconnect the gear shift cables from the gearbox.

Is the gear selector lever difficult to operate?
Yes Install new gear shift cables.
REFER TO: Gear Shift Cables - 1.6 L Duratec-16V Ti-VCT (88 kW/120 L PS) - Sigma, 5-Speed Manual Transmission - B5A/5-Speed Manual Transmission - B5/IB5 (308-06 External Manual Transmission Controls - 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).
REFER TO: Gear Shift Cables - 6-Speed Manual Transmission - B6 (308-06 External Manual Transmission Controls - 5-Speed Manual Transmission Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).
No Install a new select mechanism.
REFER TO: Selector Mechanism (308-03B Manual Transmission - 6-Speed Manual Transmission - B6, Removal and Installation).

Test yourself

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