308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6	2014 Fiesta
Diagnosis and Testing	Procedure revision date: 04/25/2013

Clutch

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.

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.
Evaluate the clutch hydraulic system.
Evaluate the clutch.
Inspect gearshift mechanism.
Evaluate the transmission.
Find the cause of the problem and correct it.

Verify Customer Concern

Verify and document the customer concern.
- During the customer interview, if a leak was noticed or if a leak is the concern, check the transmission fluid level. The vehicle should not be driven if the transmission fluid level is low.
- When was it first noticed?
- Did it appear suddenly or gradually?
- Did anything unusual occur that would coincide with it or precede it?

Identify when the condition occurs:
- Hot or cold vehicle operating conditions?
- Type of terrain?
- City/highway driving?
- Driving at a particular speed, coasting, hard acceleration?
- Shifting, upshifts, downshifts, in a particular gear, in all gears?
Has the transmission/clutch been repaired before or components installed?
- Check the vehicle service record. Note any repairs.

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: 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.

Check the transmission fluid condition.
- Allow the transmission fluid to drip onto a white cloth and examine the stain. Check the transmission fluid for contamination or metal particles.

Evaluate Clutch Hydraulic System

Verify the clutch hydraulic fluid reservoir is filled to the correct level.
- If the clutch hydraulic fluid level is correct, proceed to clutch check.
- 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

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.

Measure the clutch reserve. GO to Pinpoint Test A

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.
- If the engine stalls, the clutch is OK.
- If the engine does not stall, the clutch is slipping. Repair as necessary.

Compare the clutch evaluation results with the following chart. The following list of conditions are typical clutch concerns.

Symptom Chart - Clutch Operation

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. For information about these practices
REFER to: About This Manual (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 Clutch diaphragm finger runout	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

Pinpoint Test(s)

PINPOINT TEST A : CLUTCH SLIPPAGE

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.

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 (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).

PINPOINT TEST B : CLUTCH CHATTER, RATTLE OR SHUDDER

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.

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 (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).

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 (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission - B6, Removal and Installation).
TEST the system for normal operation.

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 (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 (303-01B Engine - 1.6L EcoBoost (132kW/180PS) - 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 (308-03B 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 (308-03B Manual Transmission - Vehicles With: 6-Speed Manual Transmission - B6, Diagnosis and Testing).

PINPOINT TEST C : CLUTCH DRAG

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)– 0.3150 in ( 8 mm)?

Yes

GO to C3

GO to C2

C3 CHECK THE BELLEVILLE SPRING WASHER OF THE CLUTCH PRESSURE PLATE

Remove transmission.
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

No	VERIFY the customer concern.

COMPONENT TEST(S)

Clutch

Slowly press and release the clutch pedal to see if the pedal is binding. Make sure the clutch pedal can be fully pressed and is not restricted by the floor mat. Verify the pedal return spring is present and is functioning correctly.

Measure the clutch reserve. GO to Pinpoint Test A

With the engine idling, the parking brake on and the clutch pedal up, gently move the gearshift lever into a forward or reverse gear, until gear clash can be heard. Slowly press the clutch pedal.

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.

Any concerns indicate a worn or damaged clutch. Repair as necessary.

With the engine idling, move the gearshift lever into 4th gear. Increase the engine to 2,000 rpm and slowly release the clutch pedal.

If the engine stalls, the clutch is OK.

If the engine does not stall, the clutch is slipping. Repair as necessary.

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 - Vehicles With: 6-Speed Manual Transmission - B6, Diagnosis and Testing).