Ford Workshop Service and Repair Manuals > Mondeo 2007.5 (02.2007-) > Mechanical Repairs | 3 Powertrain | 308 Manual Transmission-Transaxle, Clutch and Transfer Case | 308-00 Manual Transmission-Transaxle and Clutch - General Information | Diagnosis and Testing

General Procedures > < 307-02 Transmission-Transaxle Cooling - Vehicles With: 6-Speed Automatic Transmission (AWF21)|Specifications

Manual Transmission/Transaxle and Clutch - General Information - Manual Transaxle and Clutch

Mondeo 2007.5 (02/2007-)

Diagnosis and Testing

General Equipment

Ford approved diagnostic tool

Inspection and Testing

Verify the customer concern.

Visually inspect for obvious signs of mechanical or electrical damage.

Resolve any obvious causes for a concern found during the visual inspection before carrying out any further tests.

If the concern persists, check the symptoms and proceed according to the Ford approved diagnostic tool instructions.

Inspection and Verification - Manual Transaxle

The following checks should be carried out before repairing or installing a new transaxle.

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

Gear Shifting Concerns

Clutch does not operate correctly.
External gearshift mechanism REFER to:
External Controls (308-06B Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75), Description and Operation),

External Controls (308-06C Manual Transmission/Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6), Description and Operation).

Transmission noise concerns

Check the engine and transmission mountings for sufficient clearance to the transmission and the body.
Other noises except gearshift noises
Go through the driving situations/tests described in the table below under the conditions described there and answer each part of the diagnosis with a "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 E. .

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: Specifications (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Specifications), Specifications (308-01C Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6), Specifications), Specifications (308-01D Clutch - Vehicles With: 6-Speed Manual Transmission (M66), Specifications).
	Diagnosis:
	Are there extremely harsh 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 and go" mode (1st gear). Check for transmission rattle during gentle acceleration and deceleration.
	Diagnosis:
	Are there noises from the powertrain in driving situations between idling speed and a maximum of 2000 rev/min which occur at a specific, vehicle-dependent vehicle/engine speed?
2	Driving situation:	0	0
	Raise 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? Longer 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. Lock 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. Switch off the engine.
	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. In diesel engines 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 and check the bell housing).

Fluid Leakage Concerns

Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the hydraulically operated clutch) or engine oil.
Check the transmission fluid level. If necessary, drain off any excess fluid.
Locate the oil leak with the aid of a fluorescent test fluid and an ultraviolet inspection lamp.
Clean the transaxle and the adjacent areas carefully before road testing.

Symptom Chart – General Concerns

Symptom Possible Sources Action

High-effort gear shifting in one or more gears
*

Synchronizer ring or synchronization damaged

*

INSTALL a new synchronizer hub with synchronizer ring set and INSTALL a new gear wheel belonging to the synchronizer unit as necessary.

-

Because of various changes and the difficulty in estimating the level of wear, a complete new installation (as described above) is recommended.

*

Clutch does not operate correctly.

*

CHECK the clutch function and the brake fluid level.

*

Internal gearshift mechanism

*

Remove the internal gearshift mechanism and check the components. - RENEW.

Clashing or scratching noise during gear shifting
*

Synchronizer hub or synchronizer ring damaged

*

INSTALL a new synchronizer hub with synchronizer ring set and INSTALL a new gear wheel belonging to the synchronizer unit as necessary.

-

Because of various changes and the difficulty in estimating the level of wear, a complete new installation (as described above) is recommended.

*

Clutch does not operate correctly.

*

CHECK the clutch function and the brake fluid level.

Gear engagement not functioning correctly
*

External gearshift mechanism damaged

*

CHECK the external gearshift mechanism for damage. If no concern is determined, REMOVE the transmission.REFER to:
Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 2.0L Duratec-HE (MI4) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.0L Duratorq-TDCi (DW) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.5L Duratec (VI5) (308-03D Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (M66), Removal).

Gear jumps out of engagement while driving
*

Missing snap rings; synchronization components damaged or worn clutch splines

*

INSTALL a new gear set, synchronizer unit and selector fork as necessary. CHECK the transmission for damage, particularly to the sliding sleeve.

*

Incorrect sliding sleeve; worn clutch splines

*

INSTALL a new gear set, synchronizer unit and selector fork as necessary. CHECK the transmission for damage, particularly to the sliding sleeve.

*

Selector forks

*

RENEW gear wheels, sliding sleeves and selector forks as necessary. CHECK the transmission for damage, particularly to the sliding sleeve.

Gearshift lever feels loose
*

Gearshift lever fixing.

*

Check the external gearshift mechanism; replace if necessary. Check gear lever mounting, external gearshift mechanism and shift cables; tighten if necessary. REFER to:
External Controls (308-06B Manual Transmission/Transaxle External Controls - Vehicles With: 5-Speed Manual Transmission (MTX-75), Description and Operation),

External Controls (308-06C Manual Transmission/Transaxle External Controls - Vehicles With: 6-Speed Manual Transmission (MMT6), Description and Operation).

*

Internal gearshift mechanism

*

Check the internal shift mechanism for play at the transmission.

Symptom Chart - Transaxle noises

Symptom Possible Sources Action

Gear wheels banging when shifting
*

Clutch worn

*

Check clutch

*

REFER to: (308-01B Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75))
Clutch (Diagnosis and Testing),

Clutch (Diagnosis and Testing),

Clutch (Diagnosis and Testing).

*

Air in the clutch system; fluid loss

*

Check the clutch system for leaks. Check the clutch master cylinder bleed screw for blockage. Remove any blockage from the clutch master cylinder bleed screw and bleed the clutch system as necessary.
REFER to: Manual Transaxle and Clutch (308-00 Manual Transmission/Transaxle and Clutch - General Information, Diagnosis and Testing).

Slight buzzing, rattling or metallic scraping noise from the transmission at 2500 to 3500 rpm when on overrun or driving without load (particularly in 2nd and 3rd gear)
*

Rotational vibration from the engine not sufficiently damped by the clutch.

*

These noises do not affect the operation and durability of the transaxle.

*

Engine speed-dependent transmission noise

*

CHECK transmission input shaft bearings. REMOVE the transmission REFER to:
Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 2.0L Duratec-HE (MI4) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.0L Duratorq-TDCi (DW) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.5L Duratec (VI5) (308-03D Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (M66), Removal).

*

Vehicle speed-dependent transmission noise

*

CHECK driveshaft tripod joints. REFER to: (205-04 Front Drive Halfshafts)
Front Halfshaft LH (Removal and Installation),

Front Halfshaft RH (Removal and Installation).

*

Steering angle-dependent transmission noise

*

CHECK differential splines for damage. Turn the differential bevel gears against one another. For this purpose, REMOVE the differential.
REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation) /
Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).

*

The engine and transaxle assembly is in contact with the body.

*

Look for points of contact and REPAIR as necessary.

*

Collar screws – engine/gearbox

*

TIGHTEN the transmission bolts.REFER to:
Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Installation),

Transmission - 2.0L Duratec-HE (MI4) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Installation),

Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Installation),

Transmission - 2.0L Duratorq-TDCi (DW) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Installation),

Transmission - 2.5L Duratec (VI5) (308-03D Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (M66), Installation).

*

Transaxle fluid level low.

*

Check the transmission fluid level.

*

Transaxle bearings and gear wheels (usually on high-mileage vehicles).

*

REMOVE the transaxle. CHECK the bearings and gear wheels and INSTALL new components as necessary.REFER to:
Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 2.0L Duratec-HE (MI4) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.0L Duratorq-TDCi (DW) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.5L Duratec (VI5) (308-03D Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (M66), Removal).

Rattling or vibration noises.
*

External selector mechanism

*

CHECK the external gearshift mechanism.

*

Front or rear engine mounting defective

*

CHECK front or rear engine mounting; RENEW if necessary.

Symptom Chart - Oil leakage

Symptom Possible Sources Action

Fluid Leakage
*

Oil seals or O-ring seals

*

CHECK the mating surfaces and INSTALL a new.

*

Fluid leak between the clutch-side and transmission-side housing halves.

*

DISASSEMBLE the transmission and clean the mating faces. CHECK the surfaces for damage. Seal the transmission using WSK-M2G348-A5 sealer.

*

Fluid leak at transmission housing bolt

*

Tighten transmission housing bolts to specified tightening torque.

Symptom Chart - Clutch

Symptom Possible Sources Action

Clutch slipping
*

No clutch pedal free play

*

Clutch diaphragm springs broken

*

Clutch disc facing broken

*

Hardened or oiled clutch disc facing surface.

*

GO to Pinpoint Test A.

Clutch chatter or shudder
*

Engine mounting defective

*

Tilted clutch disc

*

GO to Pinpoint Test B.

Clutch disengages too late or not at all; high-effort gear shifting
*

Insufficient fluid.

*

Air in hydraulic system.

*

Excessive clutch pedal free play

*

Clutch diaphragm springs broken

*

Clutch disc deformed or broken

*

Corrosion on clutch disc splines

*

Insufficient or no grease on the transmission input shaft and clutch disc splines

*

GO to Pinpoint Test C.

Clutch pedal pulsating
*

Uneven diaphragm spring fingers

*

Frequency modulator defective (if present)

*

GO to Pinpoint Test D.

Excessive noise
*

Release bearing defective

*

Driveshaft guide bearing

*

Excessive crankshaft end play.

*

GO to Pinpoint Test E.

Fluid Leakage
*

Clutch master cylinder

*

Clutch slave cylinder

*

Hydraulic lines in area of engine and transmission

*

GO to Pinpoint Test F.

Pinpoint test

PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER

TEST CONDITIONS DETAILS/RESULTS/ACTIONS

B1: TEST CLUTCH CHATTER OR SHUDDER

1

Ignition switch in position III.

2

Start the engine, depress the clutch and engage first gear.

3

Run the engine at between 1200 rpm and 1500 rpm.

4

Release the clutch pedal slowly.

Does the vehicle jerk when it starts off?

Yes

GO to B2.

No

Clutch OK.

B2: TEST ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR

1

Check the engine/transaxle mountings isolator and roll resistor for damage or loose bolts.

Is the engine/transaxle isolator or roll restrictor loose or damaged?

Yes

TIGHTEN the bolts or INSTALL new bolts as necessary. CHECK system operates correctly

No

GO to B3.

B3: TEST CLUTCH PRESSURE PLATE

1

Remove clutch pressure plate.

Is the clutch pressure plate damaged?

Yes

RENEW the clutch set.

No

GO to B4.

B4: TEST CLUTCH FRICTION DISK

1

CHECK the clutch disc.

Does the clutch disc show evidence of damage due to tilting?

Yes

RENEW the clutch set.

No

CHECK flywheel.

PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL

TEST CONDITIONS DETAILS/RESULTS/ACTIONS

C1: CHECK FLUID LEVEL

1

Check brake fluid level

Is the brake fluid level between the MAX and MIN marks on the brake fluid reservoir?

Yes

GO to C2.

No

Fill with brake fluid, CHECK the brake and clutch systems for leaks.

C2: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL

1

Bleed the clutch system.

Does the clutch show improved disengaging characteristics following bleeding of the system?

Yes

Clutch OK.

No

GO to C3.

C3: CHECK CLUTCH PEDAL FREE PLAY

1

Measure the clutch pedal free play.

2

Depress the clutch pedal by hand until an increase in resistance is clearly felt, then release the clutch pedal again.

Is the clutch pedal free play approx. 10 mm?

Yes

GO to C4.

No

CHECK that the clutch pedal moves freely; remove if necessary.

C4: CHECK THE CLUTCH DIAPHRAGM SPRING

1

Remove the transmission and CHECK the clutch diaphragm spring.REFER to:
Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 2.0L Duratec-HE (MI4) (308-03B Manual Transmission/Transaxle - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal),

Transmission - 1.8L Duratorq-TDCi (Lynx) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.0L Duratorq-TDCi (DW) Diesel (308-03C Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal),

Transmission - 2.5L Duratec (VI5) (308-03D Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (M66), Removal).

Is the clutch diaphragm spring broken?

Yes

RENEW the clutch set. TEST the system for normal operation.

No

GO to C5.

C5: TEST CLUTCH FRICTION DISK

1

Remove the clutch disc.

Is the clutch disc bent or broken?

Yes

RENEW the clutch set.

No

GO to C6.

C6: CHECK THE SPLINES ON THE CLUTCH DISC FOR INSUFFICIENT LUBRICATION AND/OR SIGNS OF CORROSION

CAUTION:Do not use solvent cleaners to clean the inside of the clutch housing or the transmission input shaft. A lint-free damp cloth should be used for cleaning. Failure to follow this instruction may result in incorrect clutch operation.

1

CHECK the splines on the clutch disc for insufficient or no grease and/or signs of corrosion.

Is there insufficient or no grease and/or signs of corrosion on the splines of the clutch disc?

Yes

CLEAN the splines of the clutch disc. GO to C7.

No

CHECK the splines of the transmission input shaft for damage or insufficient or no grease and signs of corrosion. CLEAN and lubricate the splines on the clutch disc with the specified lubricant as required. CLEAN the splines of the transmission input shaft. If the transmission input shaft is damaged, REPLACE the components as required. TEST the system for normal operation.

C7: CHECK THE SPLINES ON THE CLUTCH DISC FOR SIGNS OF DAMAGE OR SIGNIFICANT FRICTION

CAUTION:Do not use solvent cleaners to clean the inside of the clutch housing or the transmission input shaft. A lint-free damp cloth should be used for cleaning. Failure to follow this instruction may result in incorrect clutch operation.

1

CHECK the splines on the clutch disc for damage or signs of significant friction.

Are there signs of damage or significant friction on the splines of the clutch disc?

Yes

RENEW the clutch set. Lubricate the splines of the clutch disc with the specified lubricant as required. TEST the system for normal operation.

No

CHECK the splines of the transmission input shaft for damage or insufficient or no grease and/or signs of corrosion. CLEAN and lubricate the splines on the clutch disc with the specified lubricant as required. CLEAN the splines of the transmission input shaft. If the transmission input shaft is damaged, REPLACE the components as required. TEST the system for normal operation.

PINPOINT TEST F : FLUID LEAKAGE

TEST CONDITIONS DETAILS/RESULTS/ACTIONS

F1: CHECK THE CLUTCH SLAVE CYLINDER

1

Check the clutch master cylinder for leaks.

Is the clutch master cylinder OK?

Yes

GO to F2.

No

RENEW the clutch master cylinder.

F2: CHECK THE CLUTCH SLAVE CYLINDER

1

Check the clutch slave cylinder for leaks.

Is the clutch slave cylinder OK?

Yes

GO to F3.

No

INSTALL a new clutch slave cylinder.

F3: INSPECT SYSTEM HYDRAULIC LINES

1

Check the hydraulic lines in area of engine and transmission for loose or damaged unions.

Are the clutch hydraulic lines OK?

Yes

CARRY OUT a road test to verify the customer concern.

No

REPAIR or INSTALL new components as necessary. CARRY OUT a road test.

Mechanical Repairs
3 Powertrain
308 Manual Transmission-Transaxle, Clutch and Transfer Case
308-00 Manual Transmission-Transaxle and Clutch - General Information
Diagnosis and Testing
Manual Transaxle and Clutch

General Procedures > < 307-02 Transmission-Transaxle Cooling - Vehicles With: 6-Speed Automatic Transmission (AWF21)|Specifications

Ford Workshop Service and Repair Manuals

Mondeo 2007.5 (02.2007-)

Mechanical Repairs 3 Powertrain 308 Manual Transmission-Transaxle, Clutch and Transfer Case 308-00 Manual Transmission-Transaxle and Clutch - General Information Diagnosis and Testing Manual Transaxle and Clutch

Mechanical Repairs 3 Powertrain 308 Manual Transmission-Transaxle, Clutch and Transfer Case 308-00 Manual Transmission-Transaxle and Clutch - General Information Diagnosis and Testing Manual Transaxle and Clutch

Mechanical Repairs
3 Powertrain
308 Manual Transmission-Transaxle, Clutch and Transfer Case
308-00 Manual Transmission-Transaxle and Clutch - General Information
Diagnosis and Testing
Manual Transaxle and Clutch

Mechanical Repairs
3 Powertrain
308 Manual Transmission-Transaxle, Clutch and Transfer Case
308-00 Manual Transmission-Transaxle and Clutch - General Information
Diagnosis and Testing
Manual Transaxle and Clutch