FORD FESTIVA 1991 Service Manual

Fig. 3: Ignition Secondary Trouble Shooting Chart

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Fig. 4: Ignition Primary Trouble Shooting Chart

STARTER TROUBLE SHOOTING
BASIC STARTER TROUBLE SHOOTING CHART
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Starter Fails to Operate
Dead battery or bad connections between starter and batteryCheck battery charge and all
wires and connections to
starter
Ignition switch faulty or misadjustedAdjust or replace ignition
switch
Open circuit between starter switch ignition terminal on starter relayCheck and repair wires and
connections as necessary
Starter relay or starter defectiveSee Testing in STARTER
article
Open solenoid pull-in wireSee Testing in STARTER
article
Starter Does Not Operate and Headlights Dim
Weak battery or dead cellCharge or replace battery as
necessary
Loose or corroded battery connectionsCheck that battery
connections are clean and
tight
Internal ground in starter windingsSee Testing in STARTER
article
Grounded starter fieldsSee Testing in STARTERS
Armature rubbing on pole shoesSee STARTER article
Page 19 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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Starter Turns but Engine Does Not Rotate
Starter clutch slippingSee STARTER article
Broken clutch housingSee STARTER article
Pinion shaft rusted or drySee STARTER article
Engine basic timing incorrectSee Ignition Timing in
TUNE-UP article
Broken teeth on engine flywheelReplace flywheel and check
for starter pinion gear damage
Starter Will Not Crank Engine
Faulty overrunning clutchSee STARTER article
Broken clutch housingSee STARTER article
Broken flywheel teethReplace flywheel and check
for starter pinion gear damage
Armature shaft sheared or reduction gear teeth strippedSee STARTER article
Weak batteryCharge or replace battery as
necessary
Faulty solenoidSee On-Vehicle Tests in
STARTER article
Poor groundsCheck all ground connections
for tight and clean
connections
Ignition switch faulty or misadjustedAdjust or replace ignition
switch as necessary
Starter Cranks Engine Slowly
Battery weak or defectiveCharge or replace battery as
necessary
Engine overheatedSee ENGINE COOLING
SYSTEM article
Engine oil too heavyCheck that proper viscosity
oil is used
Poor battery-to-starter connectionsCheck that all between
battery and starter are clean
and tight
Current draw too low or too highSee Bench Tests in
STARTER article
Bent armature, loose pole shoes screws or worn bearingsSee STARTER article
Burned solenoid contactsReplace solenoid
Faulty starterReplace starter
S t a r t e r E n ga ge s E n gin e On l y M o me n t a r il y
Engine timing too far advancedSee Ignition Timing in
TUNE-UP article
Overrunning clutch not engaging properlyReplace overrunning clutch.
See STARTER article
Broken starter clutchSee STARTER article
Broken teeth on engine flywheelReplace flywheel and check
starter pinion gear for damage
Weak drive assembly thrust springSee STARTER article
Weak hold-in coilSee Bench Tests in
STARTER article
Starter Drive Will Not Engage
Defective point assemblySee Testing in STARTER
article
Poor point assembly groundSee Testing in STARTER
article
Defective pull-in coilReplace starter solenoid
Starter Relay Does Not Close
Dead batteryCharge or replace battery as
necessary
Faulty wiringCheck all wiring and
connections leading to relay
Neutral safety switch faultyReplace neutral safety switch
Starter relay faultyReplace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountingsTighten starter attach bolts
Worn drive end bushingSee STARTER article
Damaged engine flywheel teethReplace flywheel and starter
pinion gear for damage
Drive yolk return spring broken or missingReplace return spring
Faulty ignition switchReplace ignition switch
Insufficient clearance between winding leads to solenoid terminal and main contact in solenoidReplace starter solenoid
Starter clutch not disengagingReplace starter clutch
Ignition starter switch contacts stickingReplace ignition switch
Starter Relay Operates but Solenoid Does Not
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TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES
BASIC SPARK PLUG TROUBLE SHOOTING CHARTS
Faulty solenoid switch, switch connections or relayCheck all wiring between
relay and solenoid or replace
relay or solenoid as necessary
Broken lead or loose soldered connectionsRepair wire or wire
connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
Weak batteryCharge or replace battery as
necessary
Solenoid contacts corrodedClean contacts or replace
solenoid
Faulty wiringCheck all wiring leading to
solenoid
Broken connections inside switch coverRepair connections or replace
solenoid
Open hold-in wireReplace solenoid
Low Current Draw
Worn brushes or weakReplace brushes or brush
springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheelAlign starter or check that
correct starter and flywheel
are being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheelFlywheel runout contributes
to the intermittent nature
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Normal Spark Plug Condition
Light Tan or Gray depositsNo Action
Electrode not burned or fouledNo Action
Gap tolerance not changedNo Action
Cold Fouling or Carbon Deposits
Overrich air/fuel mixtureAdjust air/fuel mixture, see
ENGINE PERFORMANCE
section
Faulty chokeReplace choke assembly, see
ENGINE PERFORMANCE
section
Clogged air filterClean and/or replace air filter
Incorrect idle speed or dirty carburetorReset idle speed and/ or clean
carburetor
Faulty ignition wiresReplace ignition wiring
Prolonged operation at idleShut engine off during long
idle
Sticking valves or worn valve guide sealsCheck valve train
Wet Fouling or Oil Deposits
Worn rings and pistonsInstall new rings and pistons
Excessive cylinder wearRebore or replace block
Excessive valve guide clearanceWorn or loose bearing
Gap Bridged
Deposits in combustion chamber becoming fused to electrodeClean combustion chamber of
deposits
Blistered Electrode
Engine overheatingCheck cooling system
Wrong type of fuelReplace with correct fuel
Loose spark plugsRetighten spark plugs
Over-advanced ignition timingReset ignition timing see
ENGINE PERFORMANCE
Pre-Ignition or Melted Electrodes
Incorrect type of fuelReplace with correct fuel
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Burned valvesReplace valves
Engine OverheatingCheck cooling system
Wrong type of spark plug, too hotReplace with correct spark
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BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS
BASIC ELECTRONIC IGNITION TROUBLE SHOOTING CHARTS - USING OSCILLOSCOPE PATTERNS
plug, see ENGINE
PERFORMANCE
Chipped Insulators
Severe detonationCheck for over-advanced
timing or combustion
Improper gapping procedureRe-gap spark plugs
Rust Colored Deposits
Additives in unleaded fuelTry different fuel brand
Water In Combustion Chamber
Blown head gasket or cracked headRepair or replace head or head
ga ske t
NOTE:Before diagnosing an electronic ignition system , ensure that all wiring is connected properly between
distributor, wiring connector and spark plugs. Ignition problem will show up either as: Engine Will Not
Start or Engine Runs Rough.
CONDITION & POSSIBLE CAUSECORRECTION
Engine Won't Start
Open circuit between distributor and bulkhead connectorRepair circuit
Open circuit between bulkhead connector and ignition switchRepair circuit
Open circuit between ignition switch and starter solenoidRepair circuit
Engine Runs Rough
Fuel lines leaking or cloggedTigh t e n fit t in g, r e mo ve
restriction
Initial timing incorrectReset ignition timing see
ENGINE PERFORMANCE
Centrifugal advance malfunctionRepair distributor advance
Defective spark plugs or wiringReplace plugs or plug wiring
Component Failure
Spark arc-over on cap, rotor or coilReplace cap, rotor or or coil
Defective pick-up coilReplace pick-up coil
Defective ignition coilReplace ignition coil
Defective vacuum unitReplace vacuum unit
Defective control moduleReplace control module
CONDITION & POSSIBLE CAUSECORRECTION
Firing Voltage Lines are the Same, but Abnormally High
Retarded ignition timingReset ignition timing, see
ENGINE PERFORMANCE
section
Fuel mixture too leanReadjust carburetor, see
ENGINE PERFORMANCE
High resistance in coil wireReplace coil wire
Corrosion in coil tower terminalClean and/or replace coil
Corrosion in distributor coil terminalClean and/or replace
distributor cap
Firing Voltage Lines are the Same but Abnormally Low
Fuel mixture too richReadjust carburetor, see
ENGINE PERFORMANCE
Breaks in coil wire causing arcingReplace coil wire
Cracked coil tower causing arcingReplace coil
Low coil outputReplace coil
Low engine compressionDetermine cause and repair
One or More, But Not All Firing Voltage Lines are Higher Than Others
Carburetor idle mixture not balancedReadjust carburetor, see
ENGINE PERFORMANCE
EGR valve stuck openClean and/or replace valve
High resistance in spark plug wiresReplace spark plug wires
Cracked or broken spark plug insulatorReplace spark plugs
Intake vacuum leakRepair leak
Defective spark plugsReplace spark plugs
Corroded spark plug terminalsReplace spark plugs
One or More, But Not All Firing Voltage Lines Are Lower Than Others
Curb idle mixture not balancedReadjust carburetor, see
ENGINE PERFORMANCE
Breaks in plug wiresReplace plug wires causing
arcing
Cracked coil tower causing arcingReplace coil
Low compressionDetermine cause and repair
Defective spark plugsReplace spark plugs
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BASIC DRIVEABILITY PROBLEMS TROUBLE SHOOTING
Corroded spark plugsReplace spark plugs
Cylinders Not Firing
Cracked distributor cap terminalsReplace distributor cap
Shorted spark plug wireDetermine cause and repair
Mechanical problem in engineDetermine cause and repair
Defective spark plugsReplace spark plugs
Spark plugs fouledReplace spark plugs
CONDITION & POSSIBLE CAUSECORRECTION
Hard Starting
Binding carburetor linkageEliminate binding
Binding choke linkageEliminate binding
Binding choke pistonEliminate binding
Restricted choke vacuumCheck vacuum lines for
blockage
Worn or dirty needle valve and seatClean carburetor, see ENGINE
PERFORMANCE
Float stickingReadjust or replace float see
the ENGINE
PERFORMANCE section
Incorrect choke adjustmentReset choke adjustment see
ENGINE PERFORMANCE
Defective coilReplace coil
Improper spark plug gapRegap spark plugs
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Detonation
Over-advanced ignition timingReset ignition timing see
ENGINE PERFORMANCE
Defective spark plugsReplace spark plugs
Fuel lines cloggedClean fuel lines
EGR system malfunctionCheck and repair EGR system
PCV system malfunctionRepair PCV system
Vacuum leaksCheck and repair vacuum
system
Loose fan beltsTighten or replace fan belts,
see ENGINE
PERFORMANCE
Restricted airflowRemove restriction
Vacuum advance malfunctionCheck distributor operation
Dieseling
Binding carburetor linkageEliminate binding
Binding throttle linkageEliminate blinding
Binding choke linkage or fast idle camEliminate binding
Defective idle solenoidReplace idle solenoid see
ENGINE PERFORMANCE
Improper base idle speedReset idle speed, see see
ENGINE PERFORMANCE
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Incorrect idle mixture settingReset idle mixture, see
ENGINE PERFORMANCE
Faulty Acceleration
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Engine cold and choke too leanAdjust choke and allow engine
to warm-up
Defective spark plugsReplace spark plugs
Defective coilReplace coil
Faulty Low Speed Operation
Clogged idle transfer slotsClean idle transfer slots, see
FUEL
Restricted idle air bleeds and passagesDisassemble and clean
carburetor, see FUEL
Clogged air cleanerReplace air filter
Defective spark plugsReplace spark plugs
Defective ignition wiresReplace ignition wire see
ENGINE PERFORMANCE
Defective distributor capReplace distributor cap
Faulty High Speed Operation
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
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Defective distributor centrifugal advanceReplace advance mechanism
Defective distributor vacuum advanceReplace advance unit
Incorrect spark plugs or plug gapCheck gap and/or replace
spark plugs
Faulty choke operationCheck choke and repair as
required
Clogged vacuum passagesRemove restrictions
Improper size or clogged main jetCheck jet size and clean, see
FUEL
Restricted air cleanerCheck filter and replace as
necessary
Defective distributor cap, rotor or coilReplace cap, rotor or coil
Misfire at All Speeds
Defective spark plugsReplace spark plugs
Defective spark plug wiresReplace spark plug wires
Defective distributor cap, rotor, or coilReplace cap, rotor, or coil
Cracked or broken vacuum hosesReplace vacuum hoses
Vacuum leaksRepair vacuum leaks
Fuel lines cloggedRemove restriction
Hesitation
Cracked or broken vacuumReplace vacuum hoses hoses
Vacuum leaksRepair Vacuum leaks
Binding carburetor linkageEliminate binding
Binding throttle linkageEliminate binding
Binding choke linkage or fast idle camEliminate binding
Improper float settingReadjust float setting, see
FUEL
Cracked or broken ignition wiresReplace ignition wires
Rough Idle, Missing or Stalling
Incorrect curb idle or fast idle speedReset idle speed, see see
ENGINE PERFORMANCE
Incorrect basic timingReset ignition timing see
ENGINE PERFORMANCE
Improper idle mixture adjustmentReset idle mixture, see
ENGINE PERFORMANCE
Improper feedback system operationCheck feedback system see
ENGINE PERFORMANCE
Incorrect spark plug gapReset spark plug gap, see
ENGINE PERFORMANCE
Moisture in ignition componentsDry components
Loose or broken ignition wiresReplace ignition wires
Damaged distributor cap or or rotorReplace distributor cap or
rotor
Faulty ignition coilReplace ignition coil
Fuel filter clogged or wornReplace fuel filter
Damaged idle mixture screwReplace idle mixture screw,
see FUEL
Improper fast idle cam adjustmentReset fast idle cam adjustment,
see TUNE- see ENGINE
PERFORMANCE
Improper EGR valve operationReplace EGR valve
Faulty PCV valve air flowReplace PCV valve
Choke binding or improper choke settingReset choke or eliminate
binding
Vacuum leakRepair vacuum leak
Improper float bowl fuel levelReset float adjustment, see
FUEL
Clogged air bleed or idle passagesClean carburetor passages, see
FUEL
Clogged or worn air cleaner filterReplace air filter
Faulty choke vacuum diaphragmReplace diaphragm, see
ENGINE PERFORMANCE
Exhaust manifold heat valve inoperativeReplace heat valve
Improper distributor spark advanceCheck distributor operation
Leaking valves or valve componentsCheck and repair valvetrain
Improper carburetor mountingRemo ve an d remo u n t
carburetor
Excessive play in distributor shaftReplace distributor
Loose or corroded wiring connectionsRepair or replace as required
Engine Surges
Improper PCV valve airflowReplace PCV valve
Vacuum leaksRepair vacuum leaks
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VACUUM PUMP - DIESEL TROUBLE SHOOTING
VACUUM PUMP (DIESEL) TROUBLE SHOOTING CHART
MANUAL TRANSMISSION
MANUAL TRANSMISSION TROUBLE SHOOTING
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING
Clogged air bleedsRemove restriction
EGR valve malfunctionReplace EGR valve
Restricted air cleaner filterReplace air filter
Cracked or broken vacuum hosesReplace vacuum hoses
Cracked or broken ignition wiresReplace ignition wires
Vacuum advance malfunctionCheck unit and replace as
necessary
Defective or fouled spark plugsReplace spark plugs
Ping or Spark Knock
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Distributor centrifugal or vacuum advance malfunctionCheck operation and replace
as necessary
Carburetor setting too leanReadjust mixture setting, see
ENGINE PERFORMANCE
Vacuum leakEliminate vacuum leak
EGR valve malfunctionReplace EGR valve
Poor Gasoline Mileage
Cracked or broken vacuumReplace vacuum hoses hoses
Vacuum leaksRepair vacuum leaks
Defective ignition wiresReplace wires
Incorrect choke settingReadjust setting, see ENGINE
PERFORMANCE
Defective vacuum advanceReplace vacuum advance
Defective spark plugsReplace spark plugs
Binding carburetor power pistonEliminate binding
Dirt in carburetor jetsClean and/or replace jets
Incorrect float adjustmentReadjust float setting, see
FUEL
Defective power valveReplace power valve, see
ENGINE PERFORMANCE
Incorrect idle speedReadjust idle speed
Engine Stalls
Improper float levelReadjust float level
Leaking needle valve and seatReplace needle valve and seat
Vacuum leaksEliminate vacuum leaks
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
NOTE:Diesel engines m echanical diagnosis is the sam e as gasoline engines for item s such as noisy valves,
bearings, pistons, etc. T he following trouble shooting covers only item s pertaining to diesel engines.
CONDITION & POSSIBLE CAUSECORRECTION
Excessive Noise
Loose pump-to-drive assembly screwsTighten screws
Loose tube on pump assemblyTighten tube
Valves not functioning properlyReplace valves
Oil Leakage
Loose end plugTighten end plug
Bad seal crimpRemove and re-crimp
seal
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
ConditionPossible Cause
Noisy In Forward GearsLow gear oil level, Loose bell housing bolts, Worn bearings or
gears
Clunk On Deceleration (FWD Only)Loose engine mounts, Worn inboard CV joints, Worn differential
pinion shaft, Side gear hub counterbore in case worn oversize
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POWERTRAIN
CLUTCH TROUBLE SHOOTING
BASIC CLUTCH TROUBLE SHOOTING CHART
Gear Clash When Shifting Forward GearsClutch Out Of Adjustment, Shift linkage damaged or out of
adjustment, Gears or synchronizers damaged, Low gear oil level
Transmission Noisy When Moving (RWD Only) Quiet In Neutral
With Clutch EngagedWorn rear outputshaft bearing
Gear RattleWorn bearings, Wrong gear oil, Low gear oil, Worn gears
Steady Ticking At Idle (Increases With RPM)Broken tooth on gear
Gear Clash When Shifting Forward GearsWorn or broken synchronizers
Loud Whine In ReverseNormal condition (1)
Noise When Stepping On ClutchBad release bearing, Worn pilot bearing
Ticking Or Screeching As Clutch Is EngagedFaulty release bearing, Uneven pressure plate fingers
Click Or Snap When Clutch Is EngagedWorn clutch fork, Worn or broken front bearing retainer
Transmission Shifts HardClutch not releasing, Shift mechanism binding, Clutch installed
backwards
Will Not Shift Into One Gear, Shifts Into All OthersBent shift fork, Worn detent balls
Locked Into Gear, Cannot ShiftClutch adjustment, Worn detent balls
Transmission Jumps Out Of GearPilot bearing worn, Bent shift fork, Worn gear teeth or face,
Excessive gear train end play, Worn synchronizers, Missing detent
ball spring, Shift mechanism worn or out of adjustment, Engine or
transmission mount bolts loose or out of adjustment, Transmission
not aligned
Shift Lever RattleWorn shift lever or detents, Worn shift forks, Worn synchronizers
sleeve
Shift Lever Hops Under AccelerationWorn engine or transmission mounts
(1)Most units use spur cut gears in reverse and are noisy
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Chattering or Grabbing
Incorrect clutch adjustmentAdjust clutch
Oil, grease or glaze on facingsDisassemble and clean or replace
Lo o se "U" jo in t fl an geSee DRIVE AXLES article
Worn input shaft splineReplace input shaft
Binding pressure plateReplace pressure plate
Binding release leverSee CLUTCH article
Binding clutch disc hubReplace clutch disc
Unequal pressure plate contactReplace worn/misaligned
components
Loose/bent clutch discReplace clutch disc
Incorrect transmission alignmentRealign transmission
Worn pressure plate, disc or flywheelReplace damaged components
Broken or weak pressure springsReplace pressure plate
Sticking clutch pedalLubricate clutch pedal & linkage
Incorrect clutch disc facingReplace clutch disc
Engine loose in chassisTighten all mounting bolts
Failure to Release
Oil or grease on clutch facingsClean or replace clutch clutch
disc
Incorrect release lever or pedal adjustmentSee CLUTCH article
Worn or broken clutch facingsReplace clutch disc
Bent clutch disc or pressure plateReplace damaged components
Clutch disc hub binding on input shaftClean or replace clutch disc
and/or input shaft
Binding pilot bearingReplace pilot bearing
Sticking release bearing sleeveReplace release bearing and/or
sleeve
Binding clutch cableSee CLUTCH article
Defective clutch masterReplace master cylinder
Defective clutch slaveReplace slave cylinder
Air in hydraulic systemBleed hydraulic system
Rattling
Weak or broken release lever springReplace spring and check
alignment
Damaged pressure plateReplace pressure plate
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DRIVE AXLE - NOISE DIAGNOSIS
Unrelated Noises
Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. Ensure
cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires,
CV/universal joints and wheel trim rings.
In certain conditions, the pitch of the exhaust gases may e gear whine. At other times, it may be mistaken for a wheel bearing rumble.
Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some non-standard tires with an
unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.
Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing the noise before disassembling
the drive axle.
Gear Noise
Broken clutch return springReplace return spring
Worn splines on clutch disc or input shaftReplace clutch disc and/or input
shaft
Worn clutch release bearingReplace release bearing
Dry or worn pilot bearingLubricate or replace pilot bearing
Unequal release lever contactAlign or replace release lever
Incorrect pedal free playAdjust free play
Warped or damaged clutch discReplace damaged components
Slipping
Pressure springs worn orRelease pressure plate
Oily, greasy or worn facingsClean or replace clutch disc
Incorrect clutch alignmentRealign clutch assembly
Warped clutch disc or pressure plateReplace damaged components
Binding release levers or clutch pedalLubricate and/or replace release
components
Squeaking
Worn or damaged releaseReplace release bearing
Dry or worn pilot or release bearingLubricate or replace assembly
Pilot bearing turning in crankshaftReplace pilot bearing and/or
crankshaft
Worn input shaft bearingReplace bearing and seal
Incorrect transmission alignmentRealign transmission
Dry release fork between pivotLubricate release fork and pivot
Heavy and/or Stiff Pedal
Sticking release bearing sleeveReplace release bearing and/or
sleeve
Dry or binding clutch pedal hubLubricate and align components
Floor mat interference with pedalLay mat flat in proper area
Dry or binding ball/fork pivotsLubricate and align components
Faulty clutch cableReplace clutch cable
Noisy Clutch Pedal
Faulty interlock switchReplace interlock switch
Self-adjuster ratchet noiseLubricate or replace self-adjuster
Speed control interlock switchLubricate or replace interlock
switch
Clutch Pedal Sticks Down
Binding clutch cableSee CLUTCH article
Springs weak in pressure plateReplace pressure plate
Binding in clutch linkageLubricate and free linkage
Noisy
Dry release bearingLubricate or replace release
bearing
Dry or worn pilot bearingLubricate or replace bearing
Worn input shaft bearingReplace bearing
Transmission Click
Weak springs in pressureReplace pressure plate plate
Release fork loose on ball studReplace release fork and/or
ball stud
Oil on clutch disc damperReplace clutch disc
Broken spring in slave cylinderReplace slave cylinder
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