table FORD FIESTA 2007 Workshop Manual

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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308-02-6 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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308-03-26 Manual Transmission/Transaxle 308-03-26
REMOVAL
Remove the heat shield. 3. Remove the center bearing cap.
19. CAUTIONS: 21. CAUTIONS:
Asupport the halfshaft. The inner joint A~upport the halfshaft. The inner joint
must not be bent more than
18 degrees.
must not be bent more than 18 degrees.
The outer joint must not be bent more than
The outer joint must not be bent more than
45 degrees. 45 degrees.
ADO not damage the halfshaft oil seal. ADO not damage the halfshaft oil seal.
N0TE:Plug the transaxle to prevent oil loss or dirt N0TE:PIug the transaxle to prevent oil loss or dirt
ingress. ingress.
Using the special tool, detach the left-hand
Detach the halfshaft and the intermediate
halfshaft from the transaxle and secure
it to
shaft from the transaxle and secure it to one
one side. side.
Discard the snap ring. Allow the oil to drain into a suitable container.
Allow the oil to drain into a suitable container.
22. Lower the vehicle.
20. N0TE:Discard the intermediate shaft center
bearing cap and locknuts.
Remove the intermediate shaft center
bearing cap.
1. Remove the locknuts.
2. Detach the heat shield.
-- -
2006.0 Fiesta 1212006 GI I 3290en
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308-03-29 Manual Transmission/Transaxle 308-03-29
REMOVAL
35. Using a suitable transmission jack, remove
the transaxle.
2006.0 Fiesta 1212006 GI I 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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308-03-34 Manual Transmission/Transaxle 308-03-34
REMOVAL
Using a suitable transmission jack, support
the transaxle. 30. Using a suitable transmission jack, remove
the transaxle.
//
28. Remove the transaxle right-hand retaining
bolts.
29. Remove the transaxle left-hand retaining
bolt.
2006.0 Fiesta luzoo6 G453416en
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308-03-39 Manual Transmission/Transaxle 308-03-39
DISASSEMBLY
2. Slide the selector shaft guide sleeve 23. Using a suitable drift remove and discard
downwards. the input shaft oil seal. i
21. Remove the selector shaft guide sleeve. 24. Remove the differential assembly and the
1. Remove and discard the selector shaft guide permanent magnet.
sleeve lower snap ring.
2. Remove the selector shaft guide sleeve.
22.
N0TE:lnstall a rubber band to the second
selector shaft to aid disassembly.
Remove the input shaft, the output shaft and
the selector forks as an assembly. 25.
Remove the reverse gear idler.
26. Remove the selector shaft and the shift
lock.
1. Remove the shift lock.
2006.0 Fiesta 1212006 G23118en
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308-0341 Manual Transmission/Transaxle 308-03-41
DISASSEMBLY AND ASSEMBLY
OF SUBASSEMBLIES
Output Shaft
Special Tool(s)
I I Remover, Bearing (Main I
I I Installer, Extension Housing I
Bushing Oil Seal
308-045
(1 6-0 1 5)
General
Eaui~ment
I Two-leg puller I
4. Remove the fourth gear and the synchronizer
ring.
1. Remove the ball bearing and the fourth gear.
Press
2. Remove the
third and fourth gear
1. Remove and discard the small snap ring.
2. Install the output shaft snap ring
.
3. Using a suitable two-leg puller, remove the
ball bearing.
Discard the output shaft snap ring and the
ball bearing.
Materials
3. Third gear synchronizer assembly.
synchronizer assembly.
1. Outer
synchronizer ring.
2. Synchronizer cone.
2006.0 Fiesta 1212006 G21539en
Name Specification I. Remove and discard the snap ring.
2. Remove the gear synchronizer, third and
Transmission
Oil
fourth gear synchronizer assembly and the
Disassembly third gear as an assembly.
WSD-M2C200-C
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