| Diagnosis and Testing Ultraviolet fluid leak detection equipment 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 - Check the operation of the clutch: Position a block of wood approximately 25 mm thick under the clutch pedal and depress the clutch pedal as far as possible. If first or second gear can be selected with the engine running and the parking brake applied, without any concerns, the clutch is OK.
- If the gear(s) cannot be selected, REFER to the Symptom Chart.
Transmission noise concerns - Check the engine and transmission support for insufficient gap between the transmission and the body.
- 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, REFER to the Pinpoint tests. | Item | Test /Results | Yes | No | | 1 | Test: | 0 | 0 | Road test the vehicle. Select 5th or 6th gear and fully depress the accelerator pedal to obtain maximum engine torque.
REFER to: Specifications (303-01A Engine - 2.4L Duratorq-Di (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel, Specifications).
| | Results: | | Very harsh vibrations from the drive train? Vibrations disappear if the accelerator pedal is released briefly. | | 1a | Test: | 0 | 0 | | Road test the vehicle. Drive the vehicle in simulated "stop and go driving conditions" (1st /2nd gear). Gently accelerate and brake to test for rattling noises from the transmission. | | Results: | | Noises from the drive train under driving conditions between engine idle speed and a maximum of 2000 rpm, which occur at a particular vehicle-related speed? | | 2 | Test: | 0 | 0 | | Raise and support the vehicle. Examine all engine, transmission and exhaust mountings with the engine turned off, during start and at idle. | | Results: | | Excessive vibration of engine/manual transmission or rattling sound during starting? Excessive time until the engine speed drops to idle speed. | | 3 | Test: | 0 | 0 | | Test front axle drive shafts and the manual transmission. Secure the wheels with chocks and engage the parking brake. Start the engine, engage 1st gear and slowly release the clutch pedal with engine at idle. | | Results: | | Engine speed does not drop, no power transferred, vehicle does not move. | | 4 | Test: | 0 | 0 | | Start the engine, place the gear lever in the neutral position and slowly release the clutch pedal. Stop the engine. | | Results: | | Hard, metallic noise from the transmission as the engine is stopping, during the last engine revolution before the engine ceases to turn, is NOT caused by the dual mass flywheel. On vehicles with diesel engines without an inlet manifold solenoid valve, the concern (hard, metallic noise) cannot be resolved by replacing the dual mass flywheel. On diesel engines with an inlet manifold solenoid valve, check the operation of the solenoid valve. | | If a rattling noise is heard as the engine stops with the clutch pedal depressed, examine the transmission casing for grease or oil residues (over 2 grams) from the dual mass flywheel (remove the starter motor and inspect the transmission casing). | - If a noise occurs in various gears at the same engine speed, check if the noise also occurs in the neutral position. If it does, the noise is not caused by the transmission.
- REFER to the Symptom Chart.
Oil leakage concerns - Check the transmission fluid level. If necessary, drain off any excess fluid.
- Clean the transmission and the adjacent areas carefully and road test the vehicle.
REFER to: Road/Roller Testing (100-00 General Information, Description and Operation).
- Using suitable ultraviolet fluid leak detection equipment, locate the leak and check whether the leaking fluid is transmission fluid, brake fluid (from the hydraulically operated clutch) or engine oil.
- REFER to the Symptom Chart.
Symptom Chart | Symptom | Possible Sources | Action | | Clutch slippage | * Clutch master cylinder. * Clutch slave cylinder. * Clutch pressure plate. * Clutch disc. * Crankshaft rear seal. * Transmission input shaft seal. | * | | Clutch chatter or shudder | * Engine and transmission mounts. | * REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing). | | * Clutch pressure plate. * Clutch disc. * Flywheel. | * | | Clutch drag | * Insufficient brake fluid. | * FILL the brake master cylinder reservoir to the MAX mark. INSPECT the brake and clutch hydraulic systems for leaks. REPAIR as necessary. | | * Air in the clutch hydraulic system. | * BLEED the system.
REFER to: Clutch System Bleeding - Vehicles With: MT82 (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
| | * Clutch pedal free travel. * Clutch pressure plate. * Clutch disc. * Pilot bearing. * Crankshaft end play. | * | | Clutch pedal pulsation | * Clutch pressure plate. * Clutch disc. | * INSTALL a new clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
| | * Crankshaft end play. | * CHECK the crankshaft end play.
REFER to: Crankshaft End Play (303-00 Engine System - General Information, General Procedures).
| | Hard shifting | * Clutch drag. | * | | * External controls. | * CHECK the external controls for wear or damage.
REFER to: External Controls (308-06C Manual Transmission/Transaxle External Controls - Vehicles With: MT82, Description and Operation).
INSTALL new components as necessary. | | * Gear wheels. | * Contact your local Technical Hotline. | | * Selector mechanism. | * Contact your local Technical Hotline. | | * Synchronizer(s). | * Contact your local Technical Hotline. | | Excessive noise | * Engine vibrations inadequately damped. | * REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing). | | * Transmission fluid level low. | * CHECK the transmission for leaks. TOP UP the transmission fluid. | | * Engine or transmission is in contact with the chassis or body. | * REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing). | | * Engine and transmission out of alignment. | * REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing). | | * External controls. | * CHECK the external controls for wear or damage.
REFER to: External Controls (308-06C Manual Transmission/Transaxle External Controls - Vehicles With: MT82, Diagnosis and Testing).
INSTALL new components as necessary. | | * Gear wheels and bearings. | * Contact your local Technical Hotline. | | * Clutch pedal. * Clutch release bearing. | * | | Fluid leakage | * Clutch master cylinder. * Clutch slave cylinder. * Clutch hydraulic lines. | * INSPECT the brake and clutch hydraulic systems for leaks. REPAIR as necessary. | | * Transmission output shaft seal. | * Contact your local Technical Hotline. | | * Transmission input shaft seal. | * Contact your local Technical Hotline. | | * Fluid leak between the transmission housing sections. | * Contact your local Technical Hotline. | | PINPOINT TEST A : CLUTCH SLIPPAGE | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | A1: TEST FOR CLUTCH SLIPPAGE | | | 1 Lock the wheels and apply the parking brake. | | | 2 Start the engine and engage fourth gear. | | | 3 Run the engine at approximately 2000 rpm. | | | 4 Release the clutch pedal slowly. | | | Does the engine stall when the clutch pedal is fully released? Yes Clutch OK. No | | A2: CHECK THE CLUTCH PEDAL OPERATION | | | 1 Fully depress and release the clutch pedal. | | | Does the pedal return to the initial position? Yes No INSTALL a new clutch master cylinder.
REFER to: Clutch Master Cylinder (308-02C Clutch Controls - Vehicles With: MT82, Removal and Installation).
TEST the system for normal operation. | | A3: CHECK THE CLUTCH DISC AND PRESSURE PLATE | | | 1 Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
| | | Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid? Yes Check the engine and transmission for leaks. INSTALL new components as necessary. TEST the system for normal operation. No INSTALL a new clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
TEST the system for normal operation. | | PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | B1: TEST FOR CLUTCH SHUDDER | | | 1 Start the engine. | | | 2 Engage the clutch and select fourth gear. | | | 3 Run the engine at approximately 2000 rpm. | | | 4 Release the clutch pedal slowly. | | | Does the clutch take up the drive smoothly? Yes Clutch is OK. No | | B2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID CONTAMINATION | | | 1 Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
| | | Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid? Yes Check the engine and transmission for leaks. INSTALL new components or contact your local Technical Hotline as necessary. TEST the system for normal operation. No | | B3: CHECK THE CLUTCH DISC AND PRESSURE PLATE | | | 1 Visually check the clutch disc and pressure plate. | | | Is the clutch disc and pressure plate worn or damaged? Yes INSTALL a new clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
TEST the system for normal operation. No CARRY OUT the flywheel clutch surface inspection.
REFER to: Flywheel Clutch Surface Inspection (303-00 Engine System - General Information, General Procedures).
TEST the system for normal operation. | | PINPOINT TEST C : CLUTCH DRAG | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | C1: CHECK THE OPERATION OF THE CLUTCH PEDAL | | | 1 Depress and release the clutch pedal. | | | Is excessive force required to depress the clutch pedal? Yes INSTALL a new clutch slave cylinder.
REFER to: Clutch Slave Cylinder (308-02C Clutch Controls - Vehicles With: MT82, Removal and Installation).
TEST the system for normal operation. No | | C2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID CONTAMINATION | | | 1 Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
| | | Is the clutch disc and pressure plate contaminated with oil or hydraulic fluid? Yes Check the engine and transmission for leaks. INSTALL new components as necessary. TEST the system for normal operation. No | | C3: CHECK THE CLUTCH DISC AND PRESSURE PLATE | | | 1 Visually check the clutch disc and pressure plate. | | | Is the clutch disc and pressure plate worn or damaged? Yes INSTALL a new clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
TEST the system for normal operation. No | | C4: CHECK THE INPUT SHAFT SPLINES | | | 1 Check that the clutch disc slides freely on the input shaft splines. | | | Does the clutch disc stick on the input shaft? Yes CHECK the clutch disc and input shaft splines for damage. INSTALL new components as necessary. TEST the system for normal operation. No Note: Vehicles with 2.3L engine must have a new pilot bearing installed whenever the transmission is removed. - Vehicles with 2.3L engine, MEASURE the crankshaft end play.
REFER to: Crankshaft End Play (303-00 Engine System - General Information, General Procedures).
| | C5: CHECK THE PILOT BEARING | | | 1 Visually check the pilot bearing. | | | Is the pilot bearing seized or worn? Yes INSTALL a new pilot bearing.
REFER to: Pilot Bearing (308-01C Clutch - Vehicles With: MT82, Removal and Installation).
TEST the system for normal operation. No MEASURE the crankshaft end play.
REFER to: Crankshaft End Play (303-00 Engine System - General Information, General Procedures).
| | PINPOINT TEST D : EXCESSIVE NOISE | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | D1: STATIC CHECK | | | 1 Depress and release the clutch pedal. | | | Is the noise apparent when the clutch is operated? Yes LUBRICATE the clutch and brake pedal shaft. TEST the system for normal operation. No | | D2: DYNAMIC CHECK | | | 1 Start the engine. | | | 2 Depress the clutch pedal. | | | Is the noise apparent when the clutch pedal is depressed? Yes REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing). No | | D3: CHECK DUAL MASS FLYWHEEL SECONDARY MASS | | | CAUTION:Do not rework the flywheel if it is distorted. CAUTION:Do not clean the dual mass flywheel with any kind of fluid. Clean the flywheel with a dry cloth only. CAUTION:Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface. NOTE:Excessive heat marks/blueing is acceptable. Do not install a new dual mass flywheel. 1 Remove the transmission.
REFER to: Transmission (308-03C Manual Transmission/Transaxle - Vehicles With: MT82, Removal).
Inspect the dual mass flywheel secondary mass. | | | Is the secondary mass free from damage? Yes No INSTALL a new dual mass flywheel. | | D4: CHECK THE DUAL MASS FLYWHEEL SECONDARY MASS ROTATION | | | 1 Rotate the dual mass flywheel secondary mass. | | | Does the secondary mass freely rotate ± 60 degrees? Yes INSTALL a new dual mass flywheel. No | | D5: CHECK DUAL MASS FLYWHEEL RING GEAR | | | 1 Inspect the dual mass flywheel ring gear. | | | Is the ring gear and trigger ring visually OK? Yes No INSTALL a new dual mass flywheel. | | D6: CHECK DUAL MASS FLYWHEEL WELD JOINT | | | 1 Inspect the dual mass flywheel along the weld joint for grease leakage. | | | Are there more than 2 grams of grease visible along the weld joint? Yes INSTALL a new dual mass flywheel. No | | D7: DUAL MASS FLYWHEEL DOWEL PINS | | | 1 Check the installation of the dual mass flywheel dowel pins. | | | Are dowel pins present and correctly installed? Yes No INSTALL a new dual mass flywheel. | | D8: DUAL MASS FLYWHEEL MOVEMENT | | | 1 Rotate the flywheel secondary mass clockwise and anticlockwise and measure the free movement. | | | Is there a maximum free movement of 5 ring gear teeth without spring resistance? Yes No INSTALL a new dual mass flywheel. | | D9: DUAL MASS FLYWHEEL FRICTION PLATE | | | | | | Is the friction plate visually OK (no damage to lugs)? Yes Dual mass flywheel OK. No INSTALL a new dual mass flywheel. | |
