check transmission fluid FORD FIESTA 2007 Workshop Manual

General Information
........................................................................\
............................. Lubricants and Greases
Transmission Fluids
........................................................................\
....................................
........................................................................\
.......................................................... Noise
Noise Insulation Materials
........................................................................\
..........................
0-Rings (Fluoroelastomer) ........................................................................\
.........................
........................................................................\
.......................................................... Paints
........................................................................\
.............................. Pressurized Equipment . . ........................................................................\
......................................................... Solder
........................................................................\
...................................................... Solvents
Sound Insulation
........................................................................\
.........................................
Suspended Loads ........................................................................\
.......................................
Transmission Brake Bands ........................................................................\
.........................
........................................................................\
................................................... Underseal
........................................................................\
............................................................ Viton
........................................................................\
....................................................... Welding
........................................................................\
.................... Warning Symbols on Vehicles
........................................................................\
................................................. White Spirit
Standard Workshop Practices
........................................................................\
....................
Vehicle in Workshop ........................................................................\
...................................
Alternative Fuel ........................................................................\
...........................................
Alternative Fuel - Do's ........................................................................\
..............................
Alternative Fuel - Do Nots ........................................................................\
........................
Towing the Vehicle ........................................................................\
......................................
Connecting a Slave Battery Using Jumper Cables ............................................................
Component Cleaning ........................................................................\
..................................
Calibration of Essential Measuring Equipment ...................................................................
Solvents. Sealants and Adhesives ........................................................................\
.............
........................................................................\
................................................. Introduction
RoadlRoller Testing ........................................................................\
....................................
Pre-Test Checks ........................................................................\
.........................................
Starting the Engine ........................................................................\
.....................................
Road or Roller Testing ........................................................................\
................................
Brake Testing ........................................................................\
..............................................
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100-00-1 4 General Information 100-00-1 4
DESCRIPTION AND OPERATION
Marigold Industrial (Blue Nitrile range)]. If gloves
become torn or contaminated on the inside they
should be replaced. Eye protection with safety
glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more
extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products
may offer some supplementary protection, but such
barrier creams should not be used in place of
protective clothing.
If accidental skin contact occurs with the fluids,
wash the area thoroughly with soap or skin
cleanser and water.
Accidental eye contact should be dealt with as per
normal first aid practices, by flushing the eyes with
an eye wash or clean cool water for
10 minutes,
after which medical attention should be obtained.
Remove and launder clothing which becomes
contaminated with the fluids. Do not place rags
contaminated with fluid in clothing pockets.
Wash thoroughly
after completing operations where
skin exposure may have occurred.
It is important that personnel do not smoke, eat or
drink whilst handling the fluids or affected
transmissions. These measures are designed to
limit the risk from accidental ingestion.
Label any decanted fluid
properlyluse an equivalent
label to that on original product containers.
Clean up any spills promptly using an inert
absorbent and wash down contaminated surfaces
with detergent and water.
Dispose of any waste fluids safely as hazardous
waste. Do
not employ used engine oils as lubricants or
for any application where appreciable skin contact
is likely to occur.
Environmental Precautions
Burning used engine oil in small space heaters or
boilers can be recommended only for units of
.
approved design. If in doubt check with the
appropriate local authority and manufacturer of
approved appliances.
Dispose of used oil and used oil filters through
authorized waste disposal contractors or licensed
waste disposal sites, or to the waste oil reclamation
trade. If in doubt, contact the relevant local
authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down
sewers or drains, or into watercourses.
Noise
Some operations may produce high noise levels,
which could, in time, damage hearing. In these
cases, suitable ear protection must be worn.
Noise Insulation Materials
See Foams, Fibre Insulation.
0-Rings (Fluoroelastomer)
See Viton.
Paints
Safety Data Sheets
See also Solvents, Chemical Materials.
Safety Data Sheets, which detail specific material handling instructions and precautions are available
from the respective national sales company, and
via internet
www.msds.ford .corn.
Used Engine Oil
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants, which may cause skin
cancer. Adequate means of skin protection and
washing facilities must be provided. Highly flammable, flammable
- observe No
Smoking policy
One Pack
Can contain harmful or toxic pigments, driers and
other components as well as solvents. Spraying
should be carried out only with adequate
ventilation.
2006.0 Fiesta 1212006 GI 7372en
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100-00-23 General Information 100-00-23
DESCRIPTION AND OPERATION
RoadIRoller Testing
I Road or roller testing may be carried out for various
reasons and a procedure detailing pre-test checks,
engine starting and stopping, pre-driving checks,
on-test checks and final checks to be completed
on completion of the test is given below.
Unless complete vehicle performance is being
checked, the full road test procedure need not be
carried out. Instead, those items particularly
relevant to the
system(s) being checked can be
extracted.
Pre-Test Checks
A WARNING:lf the brake system hydraulic
fluid level is low, pedal travel is excessive
or a hydraulic leak is found, do not attempt
to road test the vehicle until the reason for
the low fluid level, excessive pedal travel
or hydraulic leak is found and rectified.
It is suggested that pre-test checks and functional
tests of those systems and circuits which affect the
safe and legal operations of the vehicle, such as
( , brakes, lights and steering, should always be
carried out before the road or roller test.
With the ignition switched off, check:
- the engine oil level.
- the engine coolant level.
- the tires, for correct pressure, compatible types
and tread patterns, and wear within limits.
- that there is sufficient fuel in the tank to
complete the test.
- all around the engine, transmission and under
the vehicle for oil, coolant, hydraulic and fuel
leaks. Make a note of any apparent leaks and
wipe off the surrounding areas to make it easier
to identify the extent of the leak on completion
of the test.
Starting the Engine
N0TE:On initial drive away from cold and within
the first 1.5 km (1 mile), do not depress the
accelerator pedal beyond half travel until the
vehicle has attained a minimum speed of
25 kmlh
(15 mileslh). Never operate at high engine speed
or with the accelerator pedal at full travel whilst the
engine is cold.
With the ignition switched off, check:
- that the parking brake is applied.
- that the gear lever is in the neutral position.
- that all instrument gauges (except fuel gauge)
read zero.
With the ignition switched on, check:
- that the ignition controlled warning lamps are
illuminated.
- that the engine temperature gauge registers a reading compatible with the engine temperature.
- that the fuel gauge registers a reading
appropriate to the fuel level in the tank.
- the operation of the parking brake warning lamp
and fluid level warning indicator.
Road or Roller Testing
A CAUTI0N:lf road testing, check the brake
operation while still traveling at low speed
before continuing with the test. If the
brakes pull to one side, or appear to be
otherwise faulty, do not continue with the
road test until the fault has been found and
rectified.
During the road or roller test, check:
- that the clutch pedal operation is not stiff or
heavy.
- that the initial gear engagement is smooth and
there is no evidence of clutch drag.
- that the parking brake control operates smoothly
and releases quickly and completely.
- that the clutch takes up the drive smoothly,
without slip or judder.
- that gear changing is smooth with no abnormal
noises or vibrations from the transmission.
- the engine power output is satisfactory, full
power is achieved, acceleration is smooth and
pedal operation is not stiff or heavy, and engine
speed returns to idle correctly.
- there is no excessive or abnormally colored
smoke from the engine under normal driving,
heavy load or overrun conditions.
- that steering operation, including power steering
(if equipped), is smooth, accurate, not
excessively heavy or with excessive free play
or vibration.
- that the steering does not pull to one side and
self centers smoothly after cornering.
2006.0 Fiesta 1212006 GI 7375en
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100-04-5 Noise, Vibration and Harshness 100-04-5
DIAGNOSIS AND TESTING
Noise Conditions
Gear noise is typically a howling or whining due
to gear damage or incorrect bearing preload. It
can occur at various speeds and driving
conditions, or it can be continuous.
Chuckle is a particular rattling noise that sounds
like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from
64
kmlh (40 mph) and can usually be heard all
the way to a stop. The frequency varies with
vehicle speed.
Knock is very similar to chuckle, though it may
be louder and occurs on acceleration or
deceleration. The
teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be caused
by the following:
worn, damaged or incorrectly installed wheel
bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually
( have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by
the following:
out-of-balance front or rear wheels.
out-of-round tires.
Shudder or vibration during acceleration may be
caused by the following:
damaged powertrainldrivetrain mounts.
excessively high constant velocity (CV) joint
operating angles caused by incorrect ride height.
Check ride height, verify correct spring rate and
check items under inoperative conditions.
Road Test
I A gear-driven unit will produce a certain amount
of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving conditions,
as on a newly paved asphalt road. The
slight noise is in no way detrimental and must be
considered normal.
The road test and customer interview (if available)
provide information needed to identify the condition
-
and give direction to the correct starting point for
diagnosis.
1. Make notes throughout the diagnosis routine.
Make sure to write down even the smallest bit
of information, because it may turn out to be the
most important.
2. Do not touch anything until a road test and a
thorough visual inspection of the vehicle have been carried out. Leave the tire pressures and
vehicle load just where they were when the
condition was first observed. Adjusting tire
pressures, vehicle load or making other
adjustments may reduce the
condition(s)
intensity to a point where it cannot be identified
clearly. It may also inject something new into
the system, preventing correct diagnosis.
3. Make a visual inspection as part of the
preliminary diagnosis routine, writing down
anything that does not look right. Note tire
pressures, but do not adjust them yet. Note
leaking fluids, loose nuts and bolts, or bright
spots where components may be rubbing
against each other. Check the load space for
unusual loads.
4. Road test the vehicle and define the condition
by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon
as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
Road Test Quick Checks more than once to
verify they are providing a valid result.
Remember, the Road Test Quick Checks may
not tell where the concern is, but they will tell
where it is not.
Road Test Quick Checks
1. 24-80 kmlh (1 5-50 mph): with light acceleration,
a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
worse at a particular engine speed and at a
particular throttle setting during acceleration at
that speed. It may also produce a moaning
sound, depending on what component is
causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2006.0 Fiesta 1212006 G37349en
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100-04-9 Noise, Vibration and Harshness 1 00-04-9
DIAGNOSIS AND TESTING
Step 3: According to each identified operating
condition (Column A, B,
C, D, E, F), check each
possible Steering System
NVH concern with the
detail symptom charts below.
Before conducting a vehicle test to identify a
NVH
concern carry out the following checks.
1. Check the tire pressures and adjust to
specification, as necessary.
2. Make sure the steering system fluid is correct,
the system is free of leaks and is operating
correctly.
3. Make sure the vehicle steering system
temperature is the same as described at the
customer interview.
4. All evaluations must take place in a relatively
quiet location.
5. The heating
- air conditioning (AIC) fan and
radio must be turned off during evaluations and
the windows closed.
Symptom Chart
Power Steering Moan Noise
Test Condition
Listen for steering moan noise with the vehicle
parked, transmission in neutral and all windows
closed in the following test conditions.
1. Engine speed at idle with no steering action.
2. Engine speed at idle with slow 90 degrees per
second turning of the steering wheel.
3. Engine speed at 1250 +I- 50 rpm with no
steering action.
4. Engine speed at 1250 +I- 50 rpm with slow 90
degrees per second turning of the steering
wheel.
2006.0 Fiesta 12/2006 G37349en
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100-04-1 0 Noise, Vibration and Harshness 100-04-10
DIAGNOSIS AND TESTING
Power Steering Whine Noise 2. Engine speed at 1800 +/- 50 rpm with slow 90
degrees turning of the steering wheel.
Test Condition 3. Engine speed at 3000 +I- 50 rpm with no
Listen for steering whine noise with the vehicle steering action.
parked, transmission in neutral and all windows
4. Engine speed at 3000
+I- 50 rpm with slow 90
closed in the following test conditions. degrees turning of the steering wheel.
1. Engine speed at 1800
+I- 50 rpm with no
steering action. Symptom
Power steering system moan
noise
- A continuous low pitched
humming noise occurs when the
steering wheel is turned and the
steering system is loaded. Noise
frequency changes with engine
rpm changes. Particularly
annoying at lower engine speed.
2006.0 Fiesta 1212006 G37349en
Possible Sources
Power steering lines.
Incorrect power steering fluid.
Power steering pump. Action
CHECK
the routing of the
power steering lines.
CHECK the power steering line
clamps are secure.
CHECK the power steering
lines for clearance from the
vehicle body, front axle cross-
member and steering gear.
FLUSH the power steering
system. REFER to: (21 1-00
)
Power Steering System
Flushing
- I .8L Duratec-HE
(M14)/1.8L Duratec-SCi
(M14)/2.OL Duratec-HE (M14)
(General Procedures),
Power Steering System
Flushing
- 3.OL Duratec-SE
(VE6)/2.5L Duratec-VE
(VE6)/3.OL Duratec-ST (VE6)
(General Procedures),
Power Steering System
Flushing
- 2.OL Duratorq-
DirrDDi (Puma) Diesel12.0L
Duratorq-TDCi (Puma)
Diesell2.2L Duratorq-TDCi
(Puma) Diesel (General
Procedures).
Pressure pulses from the power
steering pump. Certain amount of
noise level acceptable, not a
safety critical item.
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100-04-15 Noise, Vibration and Harshness 100-04-15
DIAGNOSIS AND TESTING
Power Steering Grinding Noise 1. Slowly turn the steering wheel from lock to lock.
Test Condition
Action
Certain amount of noise level
acceptable, not a safety critical
item.
Symptom
Power steering system toc-toc
noise - a metallic noise created
when changing direction of
steering wheel rotation during
parking manoeuvre or at stand-
still.
2. Tilt and extend the steering column in various
positions and slowly turn the steering wheel
Possible Sources
gear (design tolerance
in steering rack).
Listen for steering grinding noise with the engine from lock to lock.
speed at idle and the vehicle parked, automatic
transmission in "P" (PARK) or manual transmission
in neutral and the windows closed.
Power Steering Zip Noise
Symptom Possible Sources Action
Power steering system grinding
noise
- an abrasive noise (like
sand paper rubbing against wood)
occurs between moving compon-
ents such as steering wheel and
the steering column shroud.
2006.0 Fiesta 1212006 G37349en
Steering wheel to shroud interfer-
ence.
Steering column bearing.
Foreign material in contact with
the steering column
shaft.
Clockspring.
Action
Certain amount of noise level
acceptable, not a safety critical item.
BLEED the power steering
system.
REFER
to: Power Steering
System Bleeding
(21 1-00
Steering System
- General
Information, General Proced-
ures).
Symptom
Power steering system zip noise
- occurs when hydraulic fluid
does not flow freely through the
power steering pump supply hose
from steering fluid reservoir to
power steering
pump causing
cavitation
at the pump. Zip is
primarily a cold weather start-up
phenomenon (below -1 0°C). Certain amount
of noise level
acceptable, not a safety critical
item.
Certain amount of noise level
acceptable, not a safety critical
item.
CHECK if floor covering is
obstructing the steering gear
pinion.
CHECK the installation of the floor
seal.
CHECK the clockspring and
secure if necessary.
REFER to: Clockspring (501
-208,
Removal and Installation).
Possible Sources
steering
Aeration of the power steering
fluid.
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205-04-9 Front Drive Halfshafts 205-04-9
REMOVAL AND INSTALLATION
6. Install the wheel and tire.
' For additional information, refer to: Wheel - and Tire (204-04 Wheels and Tires, Removal
and Installation).
7m CAUTION:^^^ a socket to tighten the
wheel hub retaining nut to prevent damage.
Tighten the wheel hub retaining nut.
8. Tighten the strut and spring assembly top
mount retaining nuts.
Vehicles with manual transaxle
9. With the vehicle on a level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
10. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill I (307-01 Automatic
Transmission/Transaxle - Vehicles With:
4-Speed Automatic Transmission
(AW81-40), General Procedures).
- - -- -
2006.0 Fiesta 1212006 GII 31 04en
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205-04-1 4 Front Drive Halfshafts 205-04-1 4
REMOVAL AND INSTALLATION
2. N0TE:lnstall a new intermediate shaft center
bearing cap and locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heatshield to the bearing cap.
3. Install the locknuts.
3. Install the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation).
Vehicles with manual transaxle
4. With the vehicle on the level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
5. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill
(307-01
Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40), General
Procedures).
2006.0 Fiesta 1212006 GI 52541 en
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206-00-26 Brake System - General Information 206-00-26
DIAGNOSIS AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
I J6: CHECK BRAKE PEDAL LINKAGE If
rn Disconnect the actuator rod from the pedal pin
and apply the brake pedal fully.
Did the pedal move freely?
-+ Yes
GO to J7.
+ No
REPAIR or INSTALL new brake pedal bush-
ings. REFER to: (206-06 Hydraulic Brake
Actuation)
Brake Pedal
- LHD, Vehicles With: Manual
Transaxle (Removal and Installation),
Brake Pedal
- LHD, Vehicles With: 4-Speed
Automatic Transmission
(AW81-40), Vehicles
With: Automated Gearshift (Removal and
Installation),
Brake Pedal
- RHD (Removal and Installation).
TEST the system for normal operation.
157: CHECK BRAKE PRESSURE CONTROL VALVE I
rn Check the brake pressure control valve for
contamination.
Is the brake fluid contaminated?
+ Yes
INSTALL a new brake pressure control valve.
FILL the brake master cylinder reservoir.
BLEED the brake system. REFER to: (206-00
Brake System
- General Information)
1 Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures). TEST the system for normal operation.
1 * Ehicle OK.
2006.0 Fiesta 1212006 G28494en
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