Focus ZX5 L4-2.0L DOHC VIN 3 (2002)
Input Shaft: Customer Interest
M/T - Clunking/Rattling Noise/Premature Clutch Wear
TSB 04-21-19
11/01/04
TRANSAXLE NOISE AT IDLE IN NEUTRAL WITH
CLUTCH PEDAL RELEASED - PREMATURE CLUTCH
WEAR
FORD:
2002-2004 Focus
This article supersedes TSB 04-12-02 to update the service procedure.
ISSUE
Some 2002-2004 SVT Focus vehicles may exhibit premature clutch wear, or a clunking and raffling noise in the transaxle, mainly at idle in neutral. The
noise can typically be reduced by fully depressing the clutch pedal. The premature clutch wear or noise may be caused by the dual mass flywheel, clutch
disc, pressure plate or by transaxle alignment.
ACTION
Refer to the following Service Procedure.
SERVICE PROCEDURE
1.
Check transaxle fluid level. If low, fill to correct level and retest for noise and proper clutch operation. If noise is still present or clutch is not
operating properly proceed to Step 2.
2.
Remove the transaxle. Refer to Workshop Manual Section 308-03C: Manual Transaxle/Transmission - MT285; Removal.
3.
Inspect the clutch slave cylinder assembly as follows:
a.
Inspect for leaks.
b.
Rotate the outer race, while applying pressure and check for roughness.
c.
Inspect for any surface scoring or burrs that may impede the sliding motion of the clutch release hub and bearing. Scoring or burrs should be
polished off with a fine grade of emery paper.
d.
Replace the clutch slave cylinder if necessary. Refer to Workshop Manual Section 308-02B: Clutch Controls - MT285/MTX75 Transaxle -
Clutch Slave Cylinder.
4.
Inspect the transaxle input shaft for damage, spline wear, burrs or rough surfaces. Scoring or burrs should be polished off with a fine grade of
emery paper. Replace the transaxle if the input shaft is damaged and cannot be repaired.
NOTE
IT IS NORMAL FOR THE INPUT SHAFT TO APPEAR POLISHED WHERE THE CLUTCH HUB SEATS, NO ACTION IS REQUIRED
UNLESS THE SPLINES ARE DAMAGED OR WORN.
5.
Remove the clutch disc, pressure plate and flywheel. Refer to Workshop Manual Section 308-01C; Clutch - MT285 Transaxle - Removal and
Installation - Clutch Disc and Pressure Plate.
6.
Inspect the rear face of the engine block as follows:
