308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6 2014 Fiesta
Diagnosis and Testing Procedure revision date: 08/21/2013

Clutch Controls

Inspection and Verification

NOTICE: If transmission noise is reported, first check the transmission fluid level. The vehicle should not be driven if the transmission fluid level is low. A low transmission fluid level will damage the transmission.

NOTE: Before attempting to repair any concerns, road test the vehicle to determine which system the concern is in.

NOTE: If an observed or reported concern is found, correct the cause before proceeding.

Gear driven units produce a certain level of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Many conditions, such as road and weather, can amplify normal vehicle noise.

The following overview is a guide to diagnose a transmission or clutch concern:

Check Fluid Level and Condition

NOTICE: The vehicle should not be driven if the transmission fluid level is low or damage may occur.

NOTICE: Excessive temperatures may break down the transmission lubricant. If there is reason to believe the transmission has been subjected to temperatures exceeding 135°C (275°F) for an extended period (greater than 20 minutes), change the lubricant immediately.

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

A low transmission fluid level can result in poor transmission shifting, engagement or damage. It also indicates a leak in the transmission seals or gaskets.

  1. Check the transmission fluid condition.

Evaluate Clutch Hydraulic System

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

Evaluate the Clutch

  1. Apply and release the clutch pedal slowly to check pedal binding. Make sure the clutch pedal can be fully applied and is not restricted by the floor mat.
  1. Measure the clutch reserve. GO to Pinpoint Test A
  1. With the engine idling and the park brake applied, move the gearshift lever into 4th gear. Increase engine speed to 2,000 rpm and slowly release the clutch pedal.
  1. Compare the clutch evaluation results with the following chart. The following list of conditions are typical clutch concerns.

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).




Condition Possible Sources Actions
Clutch slippage
  • Clutch pedal reserve
  • Worn or damaged pressure plate
  • Clutch disc facing
  • Hardened or oiled clutch disc facing surface
  • Flywheel
  GO to Pinpoint Test A
Clutch chatter, rattle or shudder
  • Loose or damaged engine or transmission mounts
  • Oil on clutch disc facing
  • 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 hydraulic system
  • Clutch pedal reserve
  • Diaphragm springs
  • Clutch disc
  • Clutch disc splines
  • Oil on clutch disc facing
  GO to Pinpoint Test C
Clutch pedal pulsation
  • Clutch and brake pedal pivot shaft not correctly lubricated
  • Flywheel
  • Worn pressure plate springs
  GO to Pinpoint Test B
Clutch related vibrations
  • Engine component grounding against frame
  • Accessory drive belt
  • Flywheel bolts loose
  • Flywheel
  • Imbalanced clutch pressure plate
  GO to Pinpoint Test B
Hard shifting
  • Insufficient clutch hydraulic fluid
  • Clutch pedal reserve
  • Transmission concern
  GO to Pinpoint Test C
Clutch system leakage
  • Clutch master cylinder
  • Clutch slave cylinder
  • Clutch hydraulic tubes
INSPECT the clutch master cylinder, the clutch slave cylinder and all hydraulic system tubes for leakage. REPAIR as necessary.


Pinpoint Test(s)


PINPOINT TEST A :
A1   TEST CLUTCH SLIPPAGE
  • Apply the parking brake.
  • Start engine and engage 4th gear.
  • Run the engine at approximately 2,000 rpm.
  • Slowly release clutch pedal.

Does the engine stall when the clutch pedal is fully released?

Yes Clutch is OK.
No GO to A2


A2   MEASURE THE CLUTCH RESERVE

NOTE: If equipped, remove the floor mat to allow the clutch pedal to travel to the downstop.

  • Install a cable tie to the clutch pedal, then attach a tape measure to the cable tie.
  • Pull the tape measure up to the steering wheel. Position it through the steering wheel opening. Put a piece of masking tape on the steering wheel and index mark the masking tape.
  • Press the clutch pedal fully and start the vehicle.
  • Shift the transmission into REVERSE gear, then move the gearshift lever forward to the position in between REVERSE gear and NEUTRAL. Slowly release the clutch pedal (if the vehicle creeps rearward, move the gearshift lever forward a little more). The transmission will work as if in NEUTRAL, but the reverse gear synchronizer will be bypassed.
  • With the clutch pedal released, gently pull the gearshift lever toward the REVERSE gear position. Gear clash can now be heard.
  • Slowly press the clutch pedal. Using the mark on the tape as a reference, note the measurement when the gear clash stops or the gearshift lever slides into REVERSE gear. Press the clutch pedal to the downstop. The difference between the measurement taken when the gear clash stopped and the measurement taken at the downstop is the clutch reserve.


    Item Pedal Position
    1 Gear clash begins
    2 Gear clash ends
    3 Clutch pedal downstop



Is the clutch reserve between 0.0394  in ( 1  mm)– 0.1181  in ( 3  mm).

Yes Clutch pedal reserve is OK. VERIFY customer concern.
No INSTALL a new pressure plate and clutch disc.
REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
or REFER to: Clutch Disc and Pressure Plate - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
or REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).




PINPOINT TEST B :
B1   CHECK THE ENGINE OR TRANSMISSION MOUNTS
  • Inspect all the engine and transmission mounts for looseness or damage.

Are any of the engine or transmission mounts loose or damaged?

Yes TIGHTEN or INSTALL new engine or transmission mounts. TEST the system for normal operation.
No GO to B2


B2   INSPECT THE PRESSURE PLATE BOLTS
  • Inspect the pressure plate-to-flywheel bolts.

Are any of the pressure plate-to-flywheel bolts loose?

Yes TIGHTEN or INSTALL new bolts.
REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
or REFER to: Clutch Disc and Pressure Plate - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
or REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).
No GO to B3


B3   INSPECT THE PRESSURE PLATE
  • Remove the clutch pressure plate.
  • Inspect the clutch pressure plate for wear or damage.

Are any signs of damage present on the clutch pressure plate?

Yes INSTALL a new clutch pressure plate.
REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
or REFER to: Clutch Disc and Pressure Plate - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
or REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).
TEST the system for normal operation.
No GO to B4


B4   CHECK THE CLUTCH DISC
  • NOTE: If the internal damper of the clutch disc is damaged or contaminated with grease or oil, it will sound similar to a "transmission rattle".
  • Check the clutch disc for wear or damage.

Is the clutch disc OK?

Yes GO to B5
No INSTALL a new clutch disc. Refer to
REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
or REFER to: Clutch Disc and Pressure Plate - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
or REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).
TEST the system for normal operation.


B5   INSPECT THE FLYWHEEL
  • Inspect the flywheel for wear or damage.

Is the flywheel OK?

Yes GO to B6
No REPAIR or INSTALL a new flywheel as necessary.
REFER to: Flywheel (303-01 Engine - 1.0L EcoBoost (90kW/120PS)) .
or REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
or REFER to: Flywheel (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
TEST the system for normal operation.


B6   INSPECT THE INPUT SHAFT
  • Inspect the input shaft for signs of wear, damage or corrosion.

Are any signs of wear damage, or corrosion present on the input shaft?

Yes If wear or damage is found, INSTALL a new input shaft.
REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly).
If corrosion is found on the splines of the input shaft, apply a small amount of grease to the splines of the input shaft.
No VERIFY the customer concern. Refer to Symptom Chart: Transmission
REFER to: Manual Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Diagnosis and Testing).
REFER to: Manual Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Diagnosis and Testing).




PINPOINT TEST C :
C1   CHECK CLUTCH FLUID LEVEL
  • Check 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 reservoir to specification, CHECK the brake and clutch systems for leaks. TEST clutch system for normal operation.


C2   TEST CLUTCH PEDAL FREE TRAVEL
  • Manually operate the clutch pedal to the point of resistance and release.
  • Measure pedal travel.

Is the measured dimension within 0.0394  in ( 1  mm)– 0.1181  in ( 3  mm)?

Yes GO to C3
No GO to C2


C3   CHECK THE BELLEVILLE SPRING WASHER OF THE CLUTCH PRESSURE PLATE
  • Remove transmission.
    REFER to: Transmission - 1.0L EcoBoost (90kW/120PS) (308-03 Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
    or REFER to: Transmission - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal).
    or REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Removal).

Does the clutch pressure plate or the Belleville spring washer of the clutch pressure plate show signs of wear or damage?

Yes INSTALL a new clutch pressure plate.
REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
or REFER to: Clutch Disc and Pressure Plate - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
or REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).
TEST the system for normal operation.
No VERIFY the customer concern.



COMPONENT TEST(S)

Clutch Hydraulic System

  1. Verify the clutch hydraulic fluid reservoir is filled to the correct level.
    1. If the fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks and repair as necessary.
    1. If the fluid is at the correct level, proceed to the next step.
  1. Apply and release the clutch pedal slowly to check for pedal binding. Make sure the clutch pedal can be fully applied and is not restricted by the floor mat. Verify the pedal return spring is present and functions correctly.
  1. Measure the clutch reserve. GO to Pinpoint Test A
  1. Set the park brake. With the clutch pedal in the up position and the engine idling, gently move the gearshift lever forward toward reverse gear until gear clash can be heard. Apply the clutch pedal slowly.
    1. If the gears cease to clash (full disengage at 25.4 mm (1 in) to 38.1 mm (1.5 in) from the floor), hold the clutch pedal at the point of disengagement and increase engine speed to 4,000 rpm. The clutch should remain disengaged, clutch OK.
  1. With the engine idling and the clutch pedal applied, move the gearshift lever into 4th gear. Increase the engine speed to 2,000 rpm and slowly release the clutch pedal.
    1. If the engine does not stall, clutch is slipping. Repair as necessary,
      REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5) .
      or REFER to: Clutch Disc and Pressure Plate - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation).
      or REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).

    1. If the engine stalls, clutch is OK.