308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6	2014 Fiesta
Diagnosis and Testing	Procedure revision date: 04/24/2013

Manual Transmission

Inspection and Verification

Verify the customer concern.

Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical
Oil leaks. Visibly damaged or worn components. Loose or missing nuts or bolts.

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

If the cause is not evident, verify the symptom and REFER to the Symptom Chart.

The following checks should be carried out before repairing or installing a new transmission.

The inspection and verification of manual transmission concerns can be considered in three main areas.

Gear Shifting Concerns

Clutch does not operate correctly.
External gearshift mechanism.
REFER to: External Controls (308-06 Manual Transmission External Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Diagnosis and Testing).

Transmission Noise Concerns

Check the engine and transmission mountings for sufficient clearance to the transmission and the body.
Any other noise excluding shift noises.
Road test the vehicle. Carry out the checks in the following table and record the results.

NOTE: If the answer is "Yes" to one or more of the tests, the transmission must be removed and the dual mass flywheel tested. For additional information GO to Pinpoint Test A

Item No.	Situation, Test / Diagnosis	Yes	No
1	Driving situation:	0	0
	Road test the vehicle. Select 5th or 6th gear and fully press the accelerator pedal to obtain maximum engine torque.
	Diagnosis:
	Are there extremely harsh vibrations from the powertrain? Vibrations disappear when the accelerator pedal is released briefly.
1a	Driving situation:	0	0
	Road test the vehicle. Drive the vehicle in simulated "stop and go" mode (1st gear). Check for transmission rattle during gentle acceleration and deceleration.
	Diagnosis:
	Are there noises from the powertrain in driving situations between idling speed and a maximum of 2000 rpm which occur at a specific, vehicle-dependent vehicle/engine speed?
2	Driving situation:	0	0
	Raise and support the vehicle. REFER to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation). Check all engine/transmission and exhaust mountings with the engine not running, while starting the engine and when it is idling.
	Diagnosis:
	Does the engine/transmission shake severely or make rattling noises during starting? Is there a longer time before the engine reaches idle speed? Install new components as necessary (engine/transmission or exhaust mountings) and repeat the test.
3	Driving situation:	0	0
	Check the front axle driveshafts and the manual transmission. Lock the wheels and apply the parking brake. Start the engine, engage 1st gear and slowly release the clutch pedal while the engine idles.
	Diagnosis:
	Engine speed does not drop, power not transferred, vehicle does not move.
4	Driving situation:	0	0
	Start the engine, place the gear lever in the neutral position and slowly release the clutch pedal. Stop the engine.
	Diagnosis:
	Hard metallic noise as the engine stops, coming from the manual transmission during the last engine revolution before the engine finally stops, is NOT caused by the dual mass flywheel.
	If a clattering noise is detected as the engine is switched off with the clutch pedal pressed, check the transmission housing for grease residues (more than 2 grams) from the dual mass flywheel. Remove the starter motor and check the bell housing. REFER to: Starter Motor (303-06B Starting System - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

Fluid Leakage Concerns

Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the hydraulically operated clutch) or engine oil.
Check the transmission fluid level. If necessary, drain off any excess fluid.
Locate the oil leak with the aid of a fluorescent test fluid and an ultraviolet inspection lamp.
Clean the transmission and the adjacent areas carefully before road testing.

Symptom Chart – Transmission Operation


Symptom	Possible Sources	Action
High-effort gear shifting in one or more gears	Synchronizer ring or synchronization damaged	INSTALL a new synchronizer hub with synchronizer ring set and INSTALL a new gear belonging to the synchronizer unit as necessary. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly). Because of various changes and the difficulty in estimating the level of wear, a complete new installation (as described above) is recommended.
	Clutch does not operate correctly.	CHECK the clutch function and the brake fluid level. REFER to: Clutch (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Diagnosis and Testing).
	Selector mechanism	Remove the selector mechanism and check the components. INSTALL new components as necessary. REFER to: Selector Mechanism (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).
Clashing or scratching noise during gear shifting	Synchronizer hub or synchronizer ring damaged	INSTALL a new synchronizer hub with synchronizer ring set and INSTALL a new gear belonging to the synchronizer unit as necessary. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly). Because of various changes and the difficulty in estimating the level of wear, a complete new installation (as described above) is recommended.
	Clutch does not operate correctly.	CHECK the clutch function and the brake fluid level. REFER to: Clutch (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Diagnosis and Testing).
Gear engagement not functioning correctly	External gearshift mechanism damaged	CHECK the external gearshift mechanism for damage. If no concern is determined, REMOVE the transmission. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Removal).
Gear jumps out of engagement while driving	Missing snap rings; synchronization components damaged or worn clutch splines	INSTALL a new gear set, synchronizer unit and selector fork as necessary. CHECK the transmission for damage, particularly to the sliding sleeve. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly).
	Incorrect sliding sleeve; worn clutch splines	INSTALL a new gear set, synchronizer unit and selector fork as necessary. CHECK the transmission for damage, particularly to the sliding sleeve. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly).
	Selector forks	INSTALL new gear wheels, sliding sleeves and selector forks as necessary. CHECK the transmission for damage, particularly to the sliding sleeve. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly).
Gearshift lever feels loose	Gearshift lever fixing	Check the gearshift mechanism; replace if necessary. Check gear lever mounting, external gearshift mechanism and shift cables; tighten if necessary. REFER to: External Controls (308-06 Manual Transmission External Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Diagnosis and Testing).
	Selector mechanism	Check the selector mechanism for play at the transmission.

Symptom Chart - Transmission NVH


Symptom	Possible Sources	Action
Gear wheels banging when shifting	Clutch worn	Check the clutch REFER to: Clutch Controls (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Diagnosis and Testing).
	Air in the clutch system; fluid loss	Check the clutch system for leaks. Check the clutch master cylinder bleed screw for blockage. Remove any blockage from the clutch master cylinder bleed screw and bleed the clutch system as necessary. REFER to: Clutch System Bleeding (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, General Procedures).
Slight buzzing, rattling or metallic scraping noise from the transmission at 2500 to 3500 rpm when on overrun or driving without load (particularly in 2nd and 3rd gear)	Rotational vibration from the engine not sufficiently damped by the clutch	These noises do not affect the operation and durability of the transmission.
	Engine speed-dependent transmission noise	CHECK transmission input shaft bearings. REMOVE the transmission. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Removal).
	Vehicle speed-dependent transmission noise	CHECK driveshaft tripod joints. REFER to: Front Drive Halfshafts (205-04 Front Drive Halfshafts, Diagnosis and Testing).
	Steering angle-dependent transmission noise	CHECK differential splines for damage. Turn the differential bevel gears against one another. For this purpose, REMOVE the differential. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly).
	The engine and transmission assembly is in contact with the body	Visually inspect for evidence of contact and REPAIR as necessary.
	Engine/transmission washer-head bolts	TIGHTEN the transmission bolts. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Installation).
	Transmission fluid level too low	Check the transmission fluid level. REFER to: Transmission Fluid Level Check (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, General Procedures).
	Transmission bearings and gear wheels (usually on high-mileage vehicles)	REMOVE the transmission. CHECK the bearings and gear wheels and INSTALL new components as necessary. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Disassembly).
Rattling or vibration noises	External gearshift mechanism	CHECK the external gearshift mechanism.
	Front or rear engine mounting defective	CHECK front or rear engine mounting; INSTALL a new mounting, if necessary.

Symptom Chart - Fluid Leakage


Symptom	Possible Sources	Action
Fluid Leakage	Oil seals or O-ring seals	CHECK the mating surfaces and INSTALL a new seal as necessary.
	Fluid leak between the clutch-side and transmission-side housing halves	DISASSEMBLE the transmission and clean the mating faces. CHECK the surfaces for damage. Seal the transmission using WSK-M2G348-A5 sealer.
	Fluid leak at transmission housing bolt	Tighten the transmission housing bolts to the specified tightening torque. REFER to: Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Assembly).

Pinpoint Tests

PINPOINT TEST A : EXCESSIVE NOISE

A1 CHECK THE TRANSMISSION AT IDLE (A)

Start the engine.

Press the clutch pedal fully.

Is the noise apparent when the clutch is operated?

Yes

GO to A2

No	There is a problem with the transmission. REFER to: Manual Transmission (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Diagnosis and Testing). .

A2 CHECK THE TRANSMISSION AT IDLE (B)

Run the engine at idle.

Are the noises coming from the pedal box?

Yes

CHECK the clutch pedal and bushings.

No	GO to A3 REFER to: Clutch Controls (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Diagnosis and Testing).

A3 CHECK THE CLUTCH RELEASE BEARING

Remove the clutch slave cylinder/release bearing assembly.
REFER to: Clutch Slave Cylinder - Vehicles With: 5-Speed Manual Transmission - B5/IB5 (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).

Check the release bearing for wear and corrosion.

Are there signs of wear or corrosion?

Yes

INSTALL a new clutch release bearing.
REFER to: Clutch Slave Cylinder - Vehicles With: 5-Speed Manual Transmission - B5/IB5 (308-02 Clutch Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Removal and Installation).

No	CHECK the crankshaft for excessive end float. Are there still noises? GO to A4

A4 CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL

NOTICE: Do not rework or machine the dual mass flywheel if it is distorted.
NOTICE: Do not clean the dual mass flywheel with any kind of liquid. Use only a dry cloth to clean the flywheel.
NOTICE: Do not clean the gap between the primary and secondary mass of the dual mass flywheel. Only clean the bolt connection surface and the clutch surface.
NOTE: Discoloration is not a reason in itself to install a new dual mass flywheel.
Remove the clutch disc and clutch pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).

Can the secondary mass of the dual mass flywheel be turned freely by more than 15 teeth?

Can spring resistance be felt in both directions?

Yes

INSTALL a new dual mass flywheel.
REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

GO to A5

A5 CHECK THE SPRING RESISTANCE

Move the secondary mass of the dual mass flywheel in both directions.

Can spring resistance be felt in both directions?

Yes

GO to A6

No	INSTALL a new dual mass flywheel. REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

A6 CHECK THE ROTATION OF THE DUAL-MASS FLYWHEEL

Secure the primary side of the dual mass flywheel.

Move the secondary side of the dual mass flywheel by hand left and right several times prior to moving on.

Twist the secondary side of the dual mass flywheel by hand in a clockwise direction until spring resistance is felt and release.

Mark the rest position on the primary and secondary sides of the dual mass flywheel.

Twist the secondary side of the dual mass flywheel by hand in a counterclockwise direction until spring resistance is felt and release.

Mark the new rest position on the primary side of the dual mass flywheel.

Count the number of teeth between the marks for both directions on the flywheel ring gear.

Are more than 5 teeth counted?

Yes

INSTALL a new dual mass flywheel.
REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

GO to A7

A7 CHECK THE DUAL MASS FLYWHEEL

Carry out a visual inspection of the dual mass flywheel.

Is the dual mass flywheel free of faults?

Yes

GO to A8

No	INSTALL a new dual mass flywheel. REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

A8 CHECK THE FLYWHEEL RING GEAR

Carry out a visual inspection of the flywheel ring gear.

Is the flywheel ring gear OK?

Yes

GO to A9

No	INSTALL a new dual mass flywheel. REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

A9 CHECK THE TRANSMISSION BELL HOUSING FOR GREASE LEAKAGE

Visually inspect the transmission bell housing for traces of grease.

Are there traces of circulated grease greater than 10 grams, 50 mm backwards from the front edge of the bell housing?

Yes

INSTALL a new dual mass flywheel.
REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

GO to A10

A10 CHECK THE GUIDE PINS OF THE DUAL MASS FLYWHEEL

NOTE: The guide pins should protrude by 0.4528 in ( 11.5 mm) +/- 0.0197 in ( .5 mm).
CHECK the installation of the guide pins of the dual mass flywheel.

Are the guide pins present and are they all the same length?

Yes

GO to A11

No	INSTALL a new dual mass flywheel. REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

A11 CHECK FOR DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING

Check the dual mass flywheel for discoloration due to overheating.

Is any discoloration evident in the marked area?

Yes

INSTALL a new dual mass flywheel.
REFER to: Flywheel (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).

No	The dual mass flywheel is OK.