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General Procedures > < Manual Transaxle and Clutch

Focus RS 2003 (09.2002-)

Manual Transmission/Transaxle and Clutch - General Information - Manual Transaxle and Clutch—2.0L Duratec-RS (Zetec) Focus RS 2003 (09/2002-)
Diagnosis and Testing

General Equipment
Ultraviolet Fluid Leak Detection Equipment

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical
  • Oil leaks - transaxle.
  • Visibly damaged or worn components.
  • Loose or missing bolts or nuts.
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. 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 transaxle.

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

Gear shifting concerns

  1. Check the operation of the clutch: Lay a block of wood approximately 25 mm thick under the clutch pedal and depress the clutch pedal as far as the stop. If first or second gear can be selected with the engine running and the parking brake applied, without any concerns, the clutch is OK.
  1. If the gear(s) cannot be selected, check the clutch pedal free travel. REFER to Section  308-02C Clutch Controls.
  1. Refer to Symptom Chart - Gear Shifting.

Transaxle noise concerns

  1. Check the engine and transaxle support for insufficient gap between the transaxle and the body.
  1. Road test the vehicle. REFER to Section  100-00 General Information.
  1. Refer to Symptom Chart - Transaxle Noises.
  1. 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 transaxle.

Oil leakage concerns

  1. Check the transaxle fluid level. If necessary, drain off any excess fluid.
  1. Clean the transaxle and the adjacent areas carefully and road test the vehicle. REFER to Section  100-00 General Information.
  1. Using suitable ultraviolet fluid leak detection equipment, locate the leak and check whether the leaking fluid is transaxle fluid, brake fluid (from the hydraulically operated clutch) or engine oil.

Symptom Chart

Symptom Possible Sources Action
Clutch slippage
*
Clutch pedal free travel.
*
Clutch master cylinder.
*
Clutch slave cylinder.
*
Clutch pressure plate.
*
Clutch disc.
*
Flywheel.
*
GO to Pinpoint Test A.
Clutch chatter or shudder
*
Engine and transaxle support insulators or roll restrictor.
*
REFER to Section  100-04 Noise, Vibration and Harshness.
*
Clutch pressure plate.
*
Clutch disc.
*
Flywheel.
*
GO to Pinpoint Test B.
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 in this section.
*
Clutch pedal free travel.
*
Clutch pressure plate warped.
*
Clutch disc warped.
*
Excessive crankshaft end play.
*
GO to Pinpoint Test C.
Clutch pedal pulsation.
*
Clutch and brake pedal pivot shaft not correctly lubricated.
*
LUBRICATE the clutch and brake pedal shaft.
*
Flywheel.
*
REMOVE the clutch disc and pressure plate. REFER to Section  308-01C Clutch. CARRY OUT the flywheel inspection. REFER to Section  303-00 Engine System - General Information.
*
Clutch pressure plate worn or damage.
*
INSTALL a new clutch disc and pressure place. REFER to Section  308-01C Clutch.
Hard shifting
*
Clutch drag.
*
GO to Pinpoint Test C.
*
Gearshift cable adjustment
*
CHECK the gearshift cable adjustment.
REFER to Gearshift Cable Adjustment in this section.
*
External controls worn or damaged.
*
REFER to Section  308-06C Manual Transmission/Transaxle External Controls.
*
Gear wheels worn or damaged.
*
DISASSEMBLE the transmission. REFER to Section  308-03C Manual Transmission/Transaxle. INSTALL new components as necessary.
*
Selector mechanism worn or damaged.
*
DISASSEMBLE the transmission. REFER to Section  308-03C Manual Transmission/Transaxle. INSTALL new components as necessary.
*
Synchronizer(s) worn or damaged.
*
DISASSEMBLE the transmission. REFER to Section  308-03C Manual Transmission/Transaxle. INSTALL new components as necessary.
Excessive noise
*
Engine vibrations inadequately damped.
*
REFER to Section  100-04 Noise, Vibration and Harshness.
*
Transaxle fluid level low.
*
CHECK the transaxle for leaks. TOP UP the transmission fluid. REFER to Section  308-03C Manual Transmission/Transaxle. CARRY OUT a road test. REFER to Section  100-00 General Information.
*
Engine or transaxle is in contact with the chassis or body.
*
REFER to Section  100-04 Noise, Vibration and Harshness.
*
Engine and transaxle out of alignment.
*
REFER to Section  100-04 Noise, Vibration and Harshness.
*
Engine to transaxle retaining bolts loose or missing.
*
INSTALL new retaining bolts as necessary. TIGHTEN the retaining bolts. REFER to Section  308-03C Manual Transmission/Transaxle.
*
External controls worn or damaged.
*
REFER to Section  308-06C Manual Transmission/Transaxle External Controls.
*
Gear wheels and bearings worn or damaged.
*
DISASSEMBLE the transmission. REFER to Section  308-03C Manual Transmission/Transaxle. INSTALL new components as necessary.
*
Clutch pedal free travel.
*
Clutch release bearing.
*
GO to Pinpoint Test D.
Fluid leakage.
*
Clutch master cylinder.
*
Clutch slave cylinder.
*
Clutch hydraulic tubes.
*
INSPECT the brake and clutch hydraulic systems for leaks. REPAIR as necessary.
NOTE:
NOTE:Check that the leak is transaxle fluid.
*
Halfshaft oil seal.
*
INSTALL a new halfshaft oil seal. REFER to Section  205-04 Front Drive Halfshafts.
*
Transaxle input shaft oil seal.
*
INSTALL a new input shaft oil seal. REFER to Section  308-03C Manual Transmission/Transaxle.
*
Oil leakage between the transaxle housing sections.
*
DISASSEMBLE the transaxle and clean the mating faces. CHECK the mating faces for damage. SEAL the transaxle with sealant. REFER to Section  308-03C Manual Transmission/Transaxle.

PINPOINT TEST A : CLUTCH SLIPPAGE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: TEST 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
GO to A2.
A2: CHECK THE CLUTCH PEDAL OPERATION
1
Measure clutch pedal travel.

Does the pedal return to the initial position?
Yes
GO to A2.
No
GO to A3.
A3: CHECK THE CLUTCH HYDRAULIC SYSTEM
1
Release the clutch slave cylinder bleed nipple.

Does the pedal return to the initial position?
Yes
INSTALL a new clutch slave cylinder. REFER to Section  308-02C Clutch Controls. TEST the system for normal operation.
No
INSTALL a new clutch master cylinder. REFER to Section  308-02C Clutch Controls. 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
GO to B2.
B2: CHECK THE CLUTCH DISC AND PRESSURE PLATE FOR OIL CONTAMINATION
1
Remove the clutch disc and pressure plate. REFER to Section  308-01C Clutch.

Is the clutch disc and pressure plate oil contaminated?
Yes
INSTALL a transaxle input shaft oil seal. REFER to Section  308-03C Manual Transmission/Transaxle. Or INSTALL a new crankshaft rear oil seal. REFER to Section  303-01F Engine.
No
GO to B3.
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 Section  308-01C Clutch. TEST the system for normal operation.
No
INSTALL a new flywheel. REFER to Section  303-01F Engine. TEST the system for normal operation.

PINPOINT TEST C : CLUTCH DRAG
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE CLUTCH PRESSURE PLATE
1
Remove the clutch disc and pressure plate. REFER to Section  308-01C Clutch.

Is the clutch disc and pressure plate worn or damaged?
Yes
INSTALL a new clutch disc and pressure plate. REFER to Section  308-01C Clutch. TEST the system for normal operation.
No
MEASURE the crankshaft end play. REFER to Section  303-00 Engine System - General Information.

PINPOINT TEST D : EXCESSIVE NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: STATIC CHECK
1
Engage the clutch and release.

Is the noise apparent when the clutch is operated?
Yes
LUBRICATE the clutch and brake pedal shaft. TEST the system for normal operation.
No
GO to D2.
D2: DYNAMIC CHECK
1
Start the engine.
2
Engage the clutch pedal.

Is the noise apparent when the clutch is engaged?
Yes
REFER to Section  303-00 Engine System - General Information.
No
INSTALL a new clutch slave cylinder. REFER to Section  308-01C Clutch. TEST the system for normal operation.

General Procedures > < Manual Transaxle and Clutch