clutch FORD FIESTA 2007 Owners Manual

308-02-8 Clutch Controls 308-02-8
REMOVAL AND INSTALLATION
Disconnect the clutch slave cylinder supply Rotate the clutch master cylinder and clutch
line from the clutch master cylinder and pedal assembly counterclockwise.
position it to one side.
Release the clutch slave cylinder supply line
retaining clip.
8. Remove the clutch master cylinder retaining
bolts.
10. Remove the clutch master cylinder.
1. Remove the clutch pedal return spring.
2. Detach the clutch master cylinder actuating
rod from the clutch pedal.
Installation
9. N0TE:Remove the clutch master cylinder
and the clutch pedal as an assembly.
All vehicles
Remove the clutch master cylinder and the 1. N0TE:Using suitable tape, secure the clutch
clutch pedal assembly.
pedal return spring in position.
Remove the pedal pivot shaft retaining nut Install the clutch master cylinder.
and remove the pivot shaft. I. Attach the clutch master cylinder actuating
rod to the clutch pedal.
2006.0 Fiesta 1212006 GI 52706en
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308-02-9 Clutch Controls 308-02-9
REMOVAL AND INSTALLATION
2. N0TE:lnstall the clutch master cylinder and
2. Install the clutch pedal return spring. Install the clutch slave cylinder supply line
the clutch pedal as an assembly: 5. Connect the clutch master cylinder supply
lnstall the clutch master cylinder and the hose
to the clutch master cylinder.
clutch pedal assembly.
Install the clutch master cylinder supply hose
I
Rotate the clutch master cylinder and the retaining
clip. I I
retaining clip. I I
clutch pedal assembly clockwise.
lnstall the pedal pivot shaft.
3. lnstall the clutch master cylinder retaining
bolts.
4. Connect the clutch slave cylinder supply line
to the clutch master cylinder.
6. Connect the clutch master cylinder supply
hose to the brake fluid reservoir.
2006.0 Fiesta 1212006 GI 52706en
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308-02-1 0 Clutch Controls 308-02-1 0
REMOVAL AND INSTALLATION
7. Bleed the clutch system. For additional
information, refer to: (308-00 Manual
Transmission/Transaxle and Clutch - General
Information)
Clutch System Bleeding (General
Procedures),
Clutch System Bleeding - Vehicles With:
Automated Gearshift
(General Procedures).
Left-hand drive vehicles
8. Install the battery tray. For additional
information, refer to:
Battery Tray (414-01,
Removal and
Installation),
Battery Tray - 2.OL Duratec-HE (M14) (414-01
Battery, Mounting and
Cables, Removal
and Installation).
9. Connect the two vacuum hoses.
Attach the vacuum hoses to the battery
clamp clip.
Right-hand drive vehicles
10. Install the air cleaner. For additional
information, refer to: (303-12 Intake Air
Distribution and
Filtering)
Air Cleaner - 1.25L Duratec-1 6V (Sigma)/l.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (Removal and lnstallation),
Air Cleaner - 1.3L Duratec-8V (Rocam)
(Removal and lnstallation),
Air Cleaner - 1.4L Duratorq-TDCi (DV) Diesel
(Removal and lnstallation),
Air Cleaner - 2.OL Duratec-HE (M14) (Removal
and lnstallation).
2006.0 Fiesta 12/2006 GI 52706en
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308-03-3 Manual Transmission/Transaxle 308-03-3
SPECIFICATIONS
Lubricants. Fluids. Sealers and Adhesives
Description Description
Sealer, fifth gear end cap
Specificat
I ions I
Specificat
ions
WSE-M4G 323-A4
Hig h-tem perature grease
Manual transmission fluid
I Description I Litres I I Super DOT 4 brake fluid I ESD-M6C5 I Manual transmission fluid (just below
/ the bottom of the filler hole)
Sealer, transaxle housing to clutch WSK-M2G
housing
1 348-A5 1
Transaxle ri
1.4L Diesel I 1.6L Diesel
First gear
Second gear
Third gear
Fourth gear Fifth gear
Reverse gear
Final drive
Reauired shim thickness
I Description I mm I
Iring shim I 3.8 I
I Shim availability (in increments of 0.1 mm) I 0.1 - 0.7 I
I Snap ring fifth gear I I .48 I
Required snap ring thickness
Description
I Clutch slave cylinder retaining bolts I 10 I - I 89
mm
Torque Specifications
I Selector gate retaining bolts I 22 I 16 I -
-housing retaining bolts I 25 I 21 I -
Ib-in
Fifth gear housing to transaxle housing retaining
bolts Ib-ft Item
I Selector mechanism to transaxle retaining bolts I 22 I 16 I -
Nm
I Reversing lamp switch I 12 I 9 I -
2006.0 Fiesta 1212006 GI 13289en
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308-0316 Manual Transrnission/Transaxle 308-03-6
DESCRIPTION AND OPERATION
Transmission construction
/"
2006.0 Fiesta 1212006 G281365en
Item Description Item Description
I
2
3
4
6
7
8
9
5th gear housing
Transmission side housing halves
Breather
Hydraulic clutch connection Slave cylinder with integral release
bearing
Input shaft
Output shaft Differential assembly
5 Clutch side housing halves
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308-03-1 7 Manual Transmission/Transaxle 308-03-1 7
DIAGNOSIS AND TESTING
Manual Transaxle
REFER to: Manual Transaxle and Clutch (308-00
Manual
Transmission/Transaxle and Clutch -
General Information, Diagnosis and Testing).
2006.0 Fiesta 12,2006 GI 8097en
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308-03125 Manual Transmission/Transaxle 308-03-25
REMOVAL
12. Disconnect the gearshift actuator electrical 1. Detach the gearshift cables and the selector
connector (colored grey). cable from the selector levers.
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket.
13. ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
All vehicles immediately washed down with cold water. 16. Remove the accessory drive belt cover.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
Vehicles without automated gearshift
14. Remove the gearshift cables cover.
I*' A~AuT10N:~rotect the ball joint seal
using a soft cloth to prevent damage.
Detach the lower arm from the wheel knuckle
15. Detach the gearshift cables from the on both
sides.
transaxle.
2006.0 Fiesta 1212006 GI 13290en
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308-03-27 Manual TransmissionlTransaxle 308-03-27
REMOVAL
23. Detach the coolant expansion tank from Discard the gasket.
, . the bracket and position it to one side.
24m ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
25. Disconnect the vehicle speed sensor (VSS)
electrical connector (if equipped).
26. Detach the exhaust flexible pipe from the
catalytic converter.
27. Remove the battery tray support bracket.
28. Remove the engine and transaxle rear
mount.
Discard the nuts.
2006.0 Fiesta 1212006 GI1 3290en
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308-03-32 Manual Transmission/'rransaxle 308-03-32
REMOVAL
2. Turn the abutment sleeve clockwise and
detach the cables from the bracket. 17' ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
/
in failure. \.
Support the exhaust flexible pipe with a
suitable support wrap or suitable splint.
13. Remove the accessory drive belt cover.
14. Remove the engine support insulator.
15. Remove the left-hand halfshaft.
For additional information, refer to: Front
Halfshaft LH
(205-04 Front Drive
Halfshafts, Removal and Installation).
16. Remove the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH
(205-04 Front Drive
Halfshafts, Removal and Installation).
18. Lower the vehicle.
Igm ACAUTION:~~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
20.
Detach the exhaust flexible pipe from the
catalytic converter.
2006.0 Fiesta 1212006 G453416en
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308-03-36 Manual Transmission/Transaxle 308-03-36
DISASSEMBLY
3. Remove the clutch slave cylinder. 2. Remove and discard the snap ring.
J'
4. Remove the vehicle speed sensor (VSS) (if 7m Remove the gearshift cable
equipped).
1. Remove the retaining pin.
2. Pull out the VSS.
5. Remove the selector mechanism cover.
6. Remove the gearshift lever.
1 . Remove the protective cap (if equipped).
8. Remove the selector lever.
Remove the bellows.
2006.0 Fiesta 1212006 G23118en
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