| Diagnosis and Testing Clutch As fault diagnosis starts when repairs are taken on, the following procedure is recommended: - Check customer concern is clear. If necessary, verify the concern on the vehicle.
- If the concern cannot be verified, perform a road test and/or use the following tables to carry out a visual inspection:
- If the concern can be clearly identified by visual inspection, rectify it and check that the system operates as it should.
- If the fault cannot be clearly identified, use the following symptom chart to identify it exactly.
Visual Inspection | Mechanical | - Fluid leaks - transmission
- Visibly damaged or worn parts
- Loose or missing nuts or bolts
| | Symptom | Possible Sources | Action | | Clutch slips | * Clutch pedal free play insufficient * Clutch pedal movement restricted (mat under the pedal) * Stiff clutch pedal * Clutch pedal travel not to specification * Clutch disc friction surface glazed or oil-fouled * Clutch disc worn out * Damaged clutch pressure plate * Damaged or weak diaphragm spring * Damaged flywheel | * | | Clutch judders | * Loose or worn engine or transmission mountings * Damaged diaphragm spring * Damaged clutch pressure plate * Clutch pressure plate friction surface overheated * Damaged flywheel * Grease or oil on the clutch disc | * | | Clutch does not disengage | * Insufficient brake fluid * Air in hydraulic system * Clutch pedal free play * Clutch belleville springs * Clutch disc * Clutch disc splines * Oil on clutch disc facing | * | | Clutch pedal pulsates | * Diaphragm spring faulty * Flywheel axial runout | * | | Unusual noises | * Damaged clutch release bearing * Excessive crankshaft end float. | * | | PINPOINT TEST A : CLUTCH SLIPS | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | A1: CHECK CLUTCH SLIP | | | 1 Chock wheels and apply handbrake. | | | 2 Ignition switch in position III. | | | 3 Start engine and engage fourth gear. Depress and hold down the clutch pedal. | | | 4 Run the engine at approximately 2000 rpm. | | | 5 Slowly release the clutch pedal, and while doing so, try to maintain the engine speed. | | | Does the engine stall when the clutch pedal is fully released? Yes Clutch OK. No | | A2: CHECK THE CLUTCH PEDAL FREE PLAY | | | 1 Press the clutch down by hand until resistance is felt, then release it again. | | | 2 Measure the clutch pedal free play | | | Is the play measured between 1 and 3 mm? Yes No | | A3: CHECK CLUTCH PEDAL | | | 1 Check lubrication. | | | Is the clutch pedal shaft adequately lubricated? Yes No Lubricate the clutch pedal shaft with high temperature grease (ESD-M1C220-A). | | A4: CHECK CLUTCH PEDAL TRAVEL | | | 1 Press the clutch pedal down by hand and release it. | | | 2 Measure the pedal travel. | | | Is the measured pedal travel 133 ± 3 mm? Yes No RENEW the clutch pedal. | | PINPOINT TEST B : CLUTCH JUDDERS | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | B1: CHECK FOR CLUTCH JUDDER | | | 1 Ignition switch in position III. | | | 2 Start engine and engage first gear. Depress and hold down the clutch pedal. | | | 3 Run the engine at between 1200 rpm and 1500 rpm. | | | 4 Release clutch pedal slowly. | | | Does the vehicle judder when it moves off? Yes No Clutch OK. | | B2: CHECK ENGINE AND TRANSMISSION MOUNTINGS | | | 1 Check engine and transmission mountings for damage or loosened bolts. | | | Are the engine or transmission mountings loose or damaged? Yes Renew damaged engine mountings and/or tighten bolts as necessary. No | | B3: CHECK THE CLUTCH PRESSURE PLATE | | | 1 Remove the clutch pressure plate. - REFER to: Clutch Disc and Pressure Plate (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Removal and Installation) / Kupplungsreibscheibe und Kupplungsdruckplatte (308-01A Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal and Installation).
- REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal and Installation) / Kupplungsreibscheibe und Kupplungsdruckplatte (308-01B Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal and Installation).
- REFER to: Kupplungsreibscheibe und Kupplungsdruckplatte (308-01C Kupplung - 2.0L Duratec-RS (Zeta), Removal and Installation).
| | | Does the clutch pressure plate display signs of wear or damage? Yes RENEW the clutch pressure plate. No | | B4: CHECK THE CLUTCH DISC | | | 1 Visual check of the clutch disc. | | | Is the clutch disc worn out (measured thickness: iB5 less than 6.5 mm, MTX 75 less than 7 mm), is it oil-fouled, or does it show signs of overheating, are cracks in the friction material visible? Yes RENEW clutch friction disc. No CHECK the flywheel. GO to Pinpoint Test G. | | PINPOINT TEST C : CLUTCH DOES NOT DISENGAGE | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | C1: CHECK THE BRAKE FLUID LEVEL | | | 1 Check the brake fluid level. | | | Is the brake fluid level between the MAX and MIN marks on the brake fluid reservoir? Yes No Top up brake fluid, check the brake and clutch systems for leaks. | | C2: CHECK CLUTCH PEDAL TRAVEL | | | 1 Press the clutch pedal down by hand and release it. | | | 2 Measure the pedal travel. | | | Is the measured pedal travel 133 ± 3 mm? Yes No RENEW the pedal. | | C3: CHECK DIAPHRAGM SPRING | | | 1 Remove the transmission. - REFER to: Transaxle - 1.6L Zetec-SE (Sigma)/1.4L (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal).
- REFER to: Transaxle - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal).
- REFER to: Getriebe - 1.6L (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal).
- REFER to: Getriebe (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal).
- REFER to: Transaxle - 2.0L Zetec-E (Zetec) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal).
- REFER to: Transaxle - 1.8L Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal).
- REFER to: Getriebe (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal).
| | | Does the clutch pressure plate or the diaphragm spring display signs of wear or damage? Yes RENEW the clutch pressure plate. No | | PINPOINT TEST D : CLUTCH PEDAL PULSATES | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | D1: CHECK CLUTCH PEDAL | | | 1 Remove the transmission. - REFER to: Transaxle - 1.6L Zetec-SE (Sigma)/1.4L (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal).
- REFER to: Transaxle - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal).
- REFER to: Getriebe - 1.6L (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal).
- REFER to: Getriebe (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal).
- REFER to: Transaxle - 2.0L Zetec-E (Zetec) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal).
- REFER to: Transaxle - 1.8L Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal).
- REFER to: Getriebe (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal).
| | | Does the clutch pressure plate or the diaphragm spring display signs of wear or damage? Yes RENEW the clutch pressure plate. No CHECK the crankshaft end float.
REFER to: Crankshaft End Play (303-00 Engine System - General Information, General Procedures).
| | PINPOINT TEST E : UNUSUAL NOISES | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | E1: CHECK TRANSMISSION NEUTRAL POSITION | | | 1 Ignition switch in position III. | | | 2 Fully depress the clutch pedal. | | | Can noises be heard when the clutch pedal is depressed? Yes No There is a problem with the transmission. GO to Pinpoint Test E. | | E2: CHECK THE CLUTCH PEDAL FREE PLAY | | | 1 Measure the pedal travel. | | | Is the play measured between 1 and 3 mm? Yes No | | E3: CHECK THE COMBINED CLUTCH SLAVE CYLINDER/RELEASE BEARING | | | 1 Remove the transmission. - REFER to: Transaxle - 1.6L Zetec-SE (Sigma)/1.4L (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal).
- REFER to: Transaxle - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal).
- REFER to: Getriebe - 1.6L (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal).
- REFER to: Getriebe (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal).
- REFER to: Transaxle - 2.0L Zetec-E (Zetec) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal).
- REFER to: Transaxle - 1.8L Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal).
- REFER to: Getriebe (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal).
| | | 2 Check clutch slave cylinder bolts. | | | 3 Check the release bearing for wear and corrosion. | | | Are the bolts loose or are there signs of wear or corrosion? Yes Tighten the bolts or RENEW the combined clutch slave cylinder/release bearing. No | | E4: CHECK THE CLUTCH DISC TORSION DAMPER | | | 1 Check the clutch disc torsion damper for wear. | | | Does the clutch disc torsion damper show signs of wear? Yes RENEW clutch disc. No CHECK the crankshaft end float.
REFER to: Crankshaft End Play (303-00 Engine System - General Information, General Procedures).
| Clutch Control As fault diagnosis starts when repairs are taken on, the following procedure is recommended: - Check customer concern is clear. If necessary, verify the concern on the vehicle.
- If the concern cannot be verified, perform a road test and/or use the following tables to carry out a visual inspection:
- If the concern can be clearly identified by visual inspection, rectify it and check that the system operates as it should.
- If the fault cannot be clearly identified, use the following symptom chart to identify it exactly.
Visual Inspection | Mechanical | - Fluid leak in clutch system.
- Visibly damaged or worn parts.
- Loose or missing bolts or nuts.
| | Symptom | Possible Sources | Action | | Clutch does not disengage | * Air in the clutch hydraulic system | * Bleed the clutch hydraulic system.
REFER to: Clutch System Bleeding - Vehicles With: 5-Speed Manual Transmission (iB5) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
| | * Brake fluid level too low. | * Top up brake fluid. | | * Clutch pedal travel not to specification | * RENEW the clutch pedal. | | Leak in the clutch hydraulic system | * Clutch master cylinder leaks * Clutch slave cylinder leaks * Leak in the clutch hydraulic lines | * | | PINPOINT TEST F : LEAK IN THE CLUTCH HYDRAULIC SYSTEM | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | F1: CHECK THE CLUTCH MASTER CYLINDER | | | 1 Check the clutch master cylinder for leaks. | | | Is the clutch master cylinder OK? Yes No RENEW clutch master cylinder. | | F2: INSPECT CLUTCH SLAVE CYLINDER | | | 1 Remove the transmission
REFER to: Transaxle - 1.6L Zetec-SE (Sigma)/1.4L (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal) /
Transaxle - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal) /
Getriebe - 1.6L (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal) /
Getriebe (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal) /
Transaxle - 2.0L Zetec-E (Zetec) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal) /
Transaxle - 1.8L Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal) /
Getriebe (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal).
or check the clutch slave cylinder for leaks. | | | Is the clutch slave cylinder OK? Yes No RENEW the combined clutch slave cylinder/release bearing. | | F3: CHECK CLUTCH HYDRAULIC LINES. | | | 1 Check the clutch hydraulic lines for loose connections and damage. | | | Are the clutch hydraulic lines OK? Yes VERIFY customer concern. No RENEW the clutch hydraulic lines. | IB5 manual transmission/MTX 75 manual transmission Diagnosis of the manual transmission is divided into three groups (Main concern A, B and C). Before performing repairs or replacing the iB5 manual transmission, the following procedure is recommended: Main concern:Gearshifts difficult to perform - Check the gearshift mechanism:
REFER to: External Controls (308-06A Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing) /
Äußere Schaltung (308-06A Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
- Check the transmission fluid level, top up if necessary.
REFER to: Specifications (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Specifications) /
Spezifikationen (308-01A Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Specifications) /
Specifications (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Specifications) /
Spezifikationen (308-01B Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Specifications) /
Spezifikationen (308-01D Kupplung - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications) /
Spezifikationen (308-03D Schaltgetriebe - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications).
| Symptom | Possible Sources | Action | | Great effort needed to change gear | * Clutch not disengaging completely | * Check clutch. GO to Pinpoint Test A. | | * Clutch disc installation position | * Remove transmission.
REFER to: Transaxle - 1.6L Zetec-SE (Sigma)/1.4L (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal) /
Transaxle - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal) /
Getriebe - 1.6L (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal) /
Getriebe (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal) /
Transaxle - 2.0L Zetec-E (Zetec) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal) /
Transaxle - 1.8L Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal) /
Getriebe (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
Check the installation position of the clutch friction disc. | | * Internal gearshift mechanism damaged or synchronizer unit damaged | * Remove the transmission and check the inner gearshift mechanism and synchronizer units, renew as necessary.
REFER to: Transaxle - 1.6L Zetec-SE (Sigma)/1.4L (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal) /
Transaxle - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec) (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Removal) /
Getriebe - 1.6L (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal) /
Getriebe (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Removal) /
Transaxle - 2.0L Zetec-E (Zetec) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal) /
Transaxle - 1.8L Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal) /
Getriebe (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Removal).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Wrong transmission fluid. | * Check that the transmission is filled with the specified transmission fluid and, if necessary, fill with transmission fluid.
REFER to: Specifications (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Specifications) /
Spezifikationen (308-01A Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Specifications) /
Specifications (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Specifications) /
Spezifikationen (308-01B Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Specifications) /
Spezifikationen (308-01D Kupplung - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications) /
Spezifikationen (308-03D Schaltgetriebe - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications).
| | Engaged gear jumps out while driving. | * Shift lever boot hardened. | * Check the outer boot on the gearshift lever and renew it if necessary.
REFER to: External Controls (308-06A Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing) /
Äußere Schaltung (308-06A Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Engine/transmission mounting loose, defective or twisted | * Check the engine/transmission mountings and renew as necessary. | | Noise when changing from one gear to another. | * Clutch not disengaging completely. | * Check clutch. GO to Pinpoint Test A. | | * Worn or damaged shift forks, synchronizer rings or synchronizer clutches (usually occur after high mileage) | * Check components for damage and renew as necessary.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | Gears cannot be engaged | * Selector cables defective | * Check the gearshift cables for damage. Renew components as necessary.
REFER to: External Controls (308-06A Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing) /
Äußere Schaltung (308-06A Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Diagnosis and Testing).
or
REFER to: External Controls (308-06B Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing) /
Äußere Schaltung (308-06B Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Diagnosis and Testing).
| | * Limited movement of inner mechanism | * Detach the shift cables from the transmission and check whether the inner gearshift mechanism is limited in its movement, if so, remove and dismantle the transmission.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | Shift is locked in one gear | * Gearshift cables defective | * Check the gearshift cables for damage. Renew components as necessary.
REFER to: External Controls (308-06A Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing) /
Äußere Schaltung (308-06A Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Diagnosis and Testing).
or
REFER to: External Controls (308-06B Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing) /
Äußere Schaltung (308-06B Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Diagnosis and Testing).
| | * Inner gearshift mechanism faulty | * Detach the shift cables from the transmission and check whether the gear shift is still locked, if so, remove and dismantle the transmission.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| Main concern:Transmission Noise - If transmission noises are reported, first check the transmission fluid level. If damage has occurred due to a lack of fluid, renew the iB5 manual transmission. Find out how much fluid is left, and make a note of it on the warranty charge request form.
- Make sure that the engine/transmission guide sleeves are fitted.
- Perform the tests / recreate the driving situations listed in the following table under the conditions given and respond to the corresponding diagnoses with "Yes" or "No".
NOTE:If the response to one or more diagnoses is "Yes", the transmission must be removed and the dual mass flywheel checked according to GO to Pinpoint Test G. | Item No. | Situation, test / diagnosis | Yes | No | | 1 | Driving situation: | 0 | 0 | Road test the vehicle. Accelerate the vehicle with maximum torque in 5th or 6th gear.
REFER to: Spezifikationen (303-01H Motor - 1.6L, Specifications).
| | Diagnosis: | | Very rough 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/go traffic" (1st/2nd gear). Check for transmission rattle during gentle acceleration and deceleration. | | Diagnosis: | | Are there noises from the drivetrain during driving conditions between engine idle and a maximum of 2000 rev/min, and which appear under particular, vehicle dependent vehicle speeds? | | 2 | Driving situation: | 0 | 0 | | Raise and support the vehicle. 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? Long time before engine reaches idle speed. Renew any damaged components (engine/transmission or exhaust mountings) and redo the test. | | 3 | Driving situation: | 0 | 0 | | Check the front axle driveshafts and the manual transmission. Chock 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 engine, put shift lever in neutral and slowly release the clutch. Turn the engine off. | | 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. On vehicles with a diesel engine and without an intake manifold flap solenoid valve, the concern (harsh, metallic noise) cannot be resolved by installing a new dual mass flywheel. On vehicles with a diesel engine and with an intake manifold flap solenoid valve, check the operation of the solenoid valve. | | If a clattering noise is detected as the engine is switched off with the clutch pedal depressed, check the transmission housing for grease residues (more than 2 grams) from the dual mass flywheel (remove the starter motor). | | Symptom | Possible Sources | Action | | Faint whirring, rattling or metallic scraping noises from the transmission when in neutral. | * Rotational vibration from the engine not sufficiently damped by the clutch. | * These noises do not affect the operation and durability of the transmission. | | Brief scratching noise during gear shifting. | * Inadequate gear synchronization. | * Fit a complete set (synchronizer hub and synchronizer rings) and renew the two gear wheels belonging to the synchronizer unit. Because of various changes and the difficulty in estimating the level of wear, complete renewal (as described above) is recommended.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Faulty clutch. | * Check clutch. GO to Pinpoint Test A. | | PINPOINT TEST G : TRANSMISSION NOISE | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | G1: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL | | | CAUTION:Do not rework the dual mass flywheel if it is distorted. CAUTION:Do not use any fluids to clean the dual mass flywheel. Clean the flywheel with a dry cloth only. CAUTION:Do not clean the gap between the primary and secondary mass. Only clean the bolt contact surface and the clutch friction surface. NOTE:Heat discoloration is not a reason to renew the dual mass flywheel. 1 Remove the clutch disc and clutch pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal and Installation).
| | | Can the secondary mass be turned freely by more than 15 teeth? Yes RENEW the dual mass flywheel. No | | G2: CHECK THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL. | | | 1 Visually inspect the secondary mass. | | | Is the secondary mass undamaged? Yes No RENEW the dual mass flywheel. | | G3: CHECK THE RING GEAR OF THE DUAL MASS FLYWHEEL | | | 1 Visually inspect the ring gear of the dual mass flywheel. | | | Is the ring gear of the dual mass flywheel OK? Yes No RENEW the dual mass flywheel. | | G4: ROTATION OF THE DUAL MASS FLYWHEEL | | | 1 Turn the secondary mass of the dual mass flywheel clockwise and counter-clockwise and measure the play. | | | Is it possible to rotate the secondary mass of the dual mass flywheel by at least 3 teeth and at most 8 teeth without spring resistance? Yes No RENEW the dual mass flywheel. | | G5: DUAL MASS FLYWHEEL GUIDE PINS | | | 1 Check the installation of the guide pins of the dual mass flywheel. | | | Are the guide pins of the dual mass flywheel present and correctly installed? Yes No RENEW the dual mass flywheel. | | G6: CHECK THE WELDED SEAM OF THE DUAL MASS FLYWHEEL | | | 1 Visually inspect the welded seam of the dual mass flywheel for loss of grease. | | | Is more than 2 grams of lost grease visible on the welded seam of the dual mass flywheel? Yes RENEW the dual mass flywheel. No Dual mass flywheel is OK. | Main concern:Fluid leakage - Check that the fluid leaking out is actually transmission fluid and not brake fluid (from the clutch hydraulic system) or engine oil.
- Check the transmission fluid level and, if necessary, drain off any excess fluid.
REFER to: Specifications (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Specifications) /
Spezifikationen (308-01A Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Specifications) /
Specifications (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Specifications) /
Spezifikationen (308-01B Kupplung - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Specifications) /
Spezifikationen (308-01D Kupplung - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications) /
Spezifikationen (308-03D Schaltgetriebe - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications).
- Locate the oil leak with the aid of a fluorescent test fluid and a UV leak tester.
- Clean the transmission and the adjacent areas thoroughly before road testing.
| Symptom | Possible Sources | Action | | Fluid leakage | * Input shaft oil seal damaged at the sealing lip | * Renew the input shaft oil seal.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Oil leakage between the transmission housing halves or in mating faces of the selector mechanism. | * Dismantle the transmission, clean the mating faces (check the surfaces for damage). Install a new oil seal on the transmission.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Transmission fluid level too high or transmission fluid with incorrect specification used | * Check the transmission fluid level, top up if necessary.
REFER to: Specifications (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Specifications) /
Spezifikationen (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Specifications) /
Specifications (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Specifications) /
Spezifikationen (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Specifications) /
Specifications (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT285), Specifications) /
Spezifikationen (308-03D Schaltgetriebe - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications).
| | * Make sure that the fluid leak is not coming from another sub-assembly (engine or power steering) | * Clearly identify the source of the leak | | * Worn or damaged components | * Detach the dust boot from the clutch bell housing before removing the transmission. Check the clutch slave cylinder, the transmission input shaft oil seal, the front halfshaft oil seals and the shift lever shaft oil seal for leaks. | | * Faint transmission fluid mist coming from the transmission breather | * Faint transmission fluid mist coming from the transmission breather is normal. If there are droplets of fluid at the transmission breather, clean the breather. | General concerns | Symptom | Possible Sources | Action | | Noises in the forward gears | * Transmission fluid level too low. | * Top up the transmission fluid.
REFER to: Specifications (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Specifications) /
Spezifikationen (308-03A Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Specifications) /
Specifications (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Specifications) /
Spezifikationen (308-03B Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Specifications) /
Specifications (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MT285), Specifications) /
Spezifikationen (308-03D Schaltgetriebe - Fahrzeuge ausgestattet mit 6-Gang Schaltgetriebe (MT285), Specifications).
| | * Engine/transmission is touching the chassis/bodywork | * Check for contact points or check for faulty engine/transmission mountings and renew as necessary | | * Engine/transmission flange bolts loose | * Tighten the engine/transmission flange bolts.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Faulty transmission, worn or defective components | * Remove the transmission and dismantle it.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | Reverse gear cannot be selected | * Faulty reversing light switch or incorrect reversing light switch installed | * Check reversing light switch and renew if necessary | | * Internal components are worn or faulty | * Remove the transmission, dismantle and check relevant components for damage.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | * Inner shift mechanism locked by foreign body | * Remove the transmission and dismantle it.
REFER to: Manual Transaxle (308-03A Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing).
or
REFER to: Manual Transaxle - Vehicles With: Manual Transaxle (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing).
| | Gearshift lever does not operate - gears cannot be engaged. | * Selector cables defective | * CHECK the shift cables and ADJUST if necessary.
REFER to: External Controls (308-06A Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (iB5), Diagnosis and Testing) /
Äußere Schaltung (308-06A Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Diagnosis and Testing).
or
REFER to: Äußere Schaltung (308-06A Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5), Diagnosis and Testing).
or
REFER to: External Controls (308-06B Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75), Diagnosis and Testing) /
Äußere Schaltung (308-06B Äußere Schaltung - Schaltgetriebe - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (MTX-75), Diagnosis and Testing).
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