FORD FIESTA 2007 Workshop Manual

308-02-1 Clutch Controls 308-02-1
SECTION 308-02 Clutch Controls
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-02-2
DESCRIPTION AND OPERATION
Clutch Controls ........................................................................\
........................................... 308-02-3
Overview ........................................................................\
.................................................... 308-02-3
Function.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-02-4
DIAGNOSIS AND TESTING
Clutch Controls ........................................................................\
........................................... 308-02-5
REMOVAL AND INSTALLATION
Clutch Slave Cylinder ........................................................................\
............. (1 6 862 4) 308-02-6
Clutch Master Cylinder ........................................................................\
........ (16 856 0) 308-02-7
i
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308-02-2 Clutch Controls 308-02-2
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Specificat
I ions 1
High-temperature grease
I Clutch slave cylinder retaining bolts I 10 I I 89 I -
Torque Specifications
1 Clutch master cylinder retaining bolts I 8 I I 71 I -
Item
I Pedal pivot shaft retaining nut I 25 I 18 I - I
2006.0 Fiesta 1212006 GII 3286en
Nm I b-ft Ib-in
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308-02-3 Clutch Controls 308-02-3
DESCRIPTION AND OPERATION
Clutch Controls
Overview
Description Item Description
2006.0 Fiesta 1212006 G281360en
5
6
4
Pressure line
Slave cylinder with choke assembly
The hydraulic clutch is supplied from a separate
Master cylinder chamber in
the brake fluid reservoir.
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Clutch Controls
DESCRIPTION
AND OPERATION
Because of this separate chamber, the braking
system remains operational if a leak occurs in the
hydraulic clutch system.
Function
Pressure is created in the master cylinder when
the clutch pedal is operated.
The hydraulic fluid in the master cylinder is put
under pressure and fed through the pressure pipe
to the slave cylinder.
The displaced hydraulic fluid moves the piston in
the slave cylinder and this in turn slides the release
bearing axially.
The release bearing pushes the bearing inner ring
against the tongues of the diaphragm spring.
The spring induced grip between the clutch disc
and the flywheel is broken.
When the clutch pedal is released the diaphragm
spring presses the piston in the slave cylinder back
to its starting position. The spring induced grip
between the clutch disc and the flywheel is created
again.
A spring in the slave cylinder ensures preload on
the release bearing.
The release bearing is always touching the
pressure plate because of this preload. The extra
travel caused by clutch lining wear is compensated
for by the preload.
There is a choke assembly in the slave cylinder
which helps to increase smoothness when pulling
away.
Because of the choke assembly, the pressure drop
of the fluid leaving the slave cylinder and returning
to the reservoir is delayed.
Because of this, the clutch closing time is delayed
when the clutch pedal is released suddenly, and
a soft and comfortable clutch engagement is
achieved.
Choking does not occur during clutch
disengagement.
A CAUTI0N:Vehicles with an automated shift
manual (ASM) transmission have
a slave
cylinder without
a choke assembly. The
slave cylinders must not be exchanged for
one another.
N0TE:The clutch pedal travel cannot be adjusted.
The release bearing is an interference fit in the
slave cylinder and cannot be renewed separately.
2006.0 Fiesta 1212006 G281360en
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308-02-5 Clutch Controls 308-02-5
DIAGNOSIS AND TESTING
Clutch Controls
REFER to: Manual Transaxle and Clutch (308-00,
Diagnosis and Testing).
2006.0 Fiesta 1212006 GI 8080en
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308-02-6 Clutch Controls 308-02-6
REMOVAL AND INSTALLATION
Clutch Slave Cylinder(l6 862 4) /'
Materials Alf brake fluid is spilt on the paintwork, the
Name Specification affected
area must be
immediately washed
ESDM-1 C220-A down with cold water. High-temperature
grease
ADO not apply grease on any area of the
clutch slave cylinder.
Removal Install the clutch slave cylinder.
I. Remove the transaxle. For additional
information, refer to: (308-03 Manual
TransmissionlTransaxle)
Transaxle - 1.2 5L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (Removal),
Transaxle - 1.3L Duratec-8V (Rocam)
(Re m ova I),
Transaxle - 2.OL Duratec-HE (M14) (Removal),
Transaxle - 1.4L Duratorq-TDCi (DV)
Dieselll.6L Duratorq-TDCi (DV) Diesel
(Removal).
2. Clean any grease and foreign material from
the input shaft.
3. CAUTIONS:
Alf brake fluid is spilt on the paintwork, the
affected area must be
immediately washed
down with
cold water.
Ausing suitable adhesive tape, cover the
input shaft
splines to prevent damage to the
input shaft
oil seal.
Remove the clutch slave cylinder.
Installation
1. CAUTIONS: 2.
Remove the adhesive tape from the input
shaft
splines.
3. Coat the input shaft splines with a thin layer
of high-temperature grease.
4.
Install the transaxle. For additional
information, refer to: (308-03 Manual
TransmissionlTransaxle)
Transaxle - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)ll .6L Duratec-1 6V
(Sigma) (Installation),
Transaxle - 1.3L Duratec-8V (Rocam)
(Installation),
Transaxle - 2.OL Duratec-HE (M14)
(Installation),
Transaxle - 1.4L Duratorq-TDCi (DV)
Dieselll.6L Duratorq-TDCi (DV) Diesel
(Installation).
2006.0 Fiesta 1212006 GI1 3288en
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308-02-7 Clutch Controls 308-02-7
REMOVAL AND INSTALLATION
Clutch Master Cylinder(l6 856 0) /
Removal 4. Remove the battery tray. For additional
information, refer to:
CAUTI0N:H brake fluid is spilt on the
paintwork, the affected area must be Battery
Tray (41 4-01, Removal and
immediately washed down with cold water. Installation),
Battery Tray - 2.OL Duratec-HE (M14) (414-01
All vehicles Battery, Mounting and Cables, Removal
and Installation).
Left-hand drive vehicles
1. Using a suitable syringe, remove brake fluid
from the brake fluid reservoir until the brake All vehicles
fluid level is at the MIN mark.
5. N0TE:Plug the brake fluid reservoir to
prevent
fluid loss or dirt ingress. Right-hand drive vehicles Disconnect the clutch master cylinder supply 2. Remove the air cleaner. For additional hose from the brake fluid reservoir.
information, refer to: (303-1 2 Intake Air
Distribution and Filtering)
Push the clip to release the clutch master
cylinder supply hose.
3. Disconnect the two vacuum hoses.
6. Remove the clutch master cylinder supply
Detach the vacuum hoses from the battery hose.
clamp clip. Release the clutch master cylinder supply
hose retaining clip.
Allow the fluid to drain into a suitable
container.
Air Cleaner - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-1 6V (Sigma)/l .6L Duratec-I 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),
(, I Air Cleaner - 2.OL Duratec-HE (M14) (Removal
and
Installation),
Air Cleaner - 1.6L Duratorq-TDCi (DV) Diesel
(Removal and lnstallation).
7. N0TE:Plug the clutch slave cylinder supply
line to prevent fluid loss or dirt ingress.
1
2006.0 Fiesta 1212006 GI 52706en
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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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