manual transmission FORD FIESTA 2007 Workshop Manual

Manual Transmission/Transaxle and Clutch -
General Information
DIAGNOSIS AND TESTING
TEST CONDITIONS
Release the clutch pedal slowly.
Does the clutch take up the drive smoothly?
-+ Yes
Clutch is OK.
-+ No
GO to
B2.
B2: CHECK THE CLUTCH DlSC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
rn Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate (308-
01 Clutch, Removal and Installation).
Is the clutch disc and pressure plate contamin-
ated with oil or hydraulic fluid?
-+ Yes
CHECK the engine and transaxle for leaks.
INSTALL new components as necessary.
TEST the system for normal operation.
-+ No
GO to B3.
B3: CHECK THE CLUTCH
DlSC AND PRESSURE PLATE
rn Visually check the clutch disc and pressure
plate.
Is the clutch disc and pressure plate worn or
damaged?
-+ Yes INSTALL a new clutch disc and pressure
plate.
REFER to: Clutch Disc and Pressure Plate
(308-01 Clutch, Removal and Installation).
TEST the system for normal operation.
-+ No
CARRY OUT the flywheel clutch surface
inspection.
REFER to: Flywheel Inspection (303-00
Engine System
- General Information,
General Procedures).
TEST the system for normal operation.
2006.0 Fiesta 12/2006 G25629en
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Manual Transmission/Transaxle and Clutch -
General Information
DIAGNOSIS AND TESTING
PINPOINT TEST C : CLUTCH DRAG
TEST CONDITIONS
Cl: CHECK THE OPERATION OF THE CLUTCH PEDAL
rn Bleed the clutch system.
REFER to: Clutch System Bleeding (308-00,
General Procedures).
Does the clutch properly disengage after
bleeding?
-, Yes
Clutch system is OK.
+ No
GO to C2.
C2: CHECK THE CLUTCH DlSC AND PRESSURE PLATE FOR OIL OR HYDRAULIC FLUID
CONTAMINATION
rn Remove the clutch disc and pressure plate.
REFER to: Clutch Disc and Pressure Plate
(308-
01 Clutch, Removal and Installation).
Is the clutch disc and pressure plate contamin-
ated with oil or hydraulic fluid?
+ Yes
CHECK the engine and transaxle for leaks.
INSTALL new components as necessary.
TEST the system for normal operation.
+ No
GO to C3.
C3: CHECK THE CLUTCH DlSC AND PRESSURE PLATE
Visually check the clutch disc and pressure
plate.
Is the clutch disc and pressure plate worn or
damaged?
-, Yes
INSTALL a new clutch disc and pressure
plate.
REFER to: Clutch Disc and Pressure Plate
(308-01 Clutch, Removal and Installation).
TEST the system for normal operation.
-, No
GO to C4.
2006.0 Fiesta 1212006 G25629en
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Manual Transmission/Transaxle and Clutch -
308-00-1 0 General Information 308-00-1 0
DIAGNOSIS
AND TESTING
TEST CONDITIONS DETAILSIRESU LTSIACTIONS
C4: CHECK THE INPUT SHAFT SPLINES
Check that the clutch disc slides freely on the
input shaft splines.
Does the clutch disc stick on the input shaft?
+ Yes
CHECK the clutch disc and input shaft splines
for damage. INSTALL new components as
necessary. TEST the system for normal
operation.
+ No
MEASURE the crankshaft end play.
REFER to: Crankshaft End Play (303-00
Engine System
- General Information,
General Procedures).
PINPOINT TEST D
: EXCESSIVE NOISE
TEST CONDITIONS
I Dl: STATIC CHECK I
Depress and release the clutch pedal.
Is the noise apparent when the clutch is oper-
ated?
+ Yes
LUBRICATE the clutch and brake pedal shaft.
TEST the system for normal operation.
I D2: DYNAMIC CHECK I
Start the engine.
Depress the clutch pedal.
Is the noise apparent when the clutch pedal is
depressed?
-+ Yes
REFER to: Engine (303-00 Engine System -
General Information, Diagnosis and Testing).
-, No
INSTALL a new clutch slave cylinder and
release bearing assembly. REFER to:
Clutch Disc and Pressure Plate (308-01 Clutch,
Removal and Installation),
Clutch Slave Cylinder (308-02 Clutch Controls,
Removal and Installation).
TEST the system for normal operation.
2006.0 Fiesta 1212006 G25629en
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Manual Transmission/Transaxle and Clutch -
308-00-1 1 General Information 308-00-1 I
GENERAL PROCEDURES
Gearshift Cable Adjustment(l6 51 3 0)

All vehicles
1. Select the 3rd gear.
2. Raise and support the vehicle.
For additional information, refer to: Jacking
(1
00-02 Jacking and Lifting, Description
and Operation).
For additional information, refer to: Lifting
(1
00-02 Jacking and Lifting, Description
and Operation).
3. Remove the gearshift cables cover.
Vehicles built up to 0812003
4. Release the selector cable adjuster locking
insert (gearshift cable box shown removed
for clarity).
Press down the orange colored clip.
Vehicles built 0812003 onwards
5. Release the selector cable adjuster locking
insert (gearshift cable box shown removed
for clarity).
Pull out the orange colored clip.
All vehicles
6. N0TE:Make sure that the selector cable
adjuster locking insert returns to the locked
position.
Lock the selector cable adjuster.
Press down the clip on the adjuster.
7. Install the gearshift cables cover.
8. Lower the vehicle.
2006.0 Fiesta 1212006 GI 52562en
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Manual Transmission/Transaxle and Clutch -
308-00-1 2 General Information 308-00-1 2
GENERAL PROCEDURES
Clutch System Bleeding(l6 843 0)
Special Tool(s) 6. Fill the reservoir of the special tool with (,, .
I Hand Vacuum approximately 100 ml of new brake fluid.
7. N0TE:Make sure that the special tool
reservoir is positioned lower than the bleed
nipple.
Install the special tool.
Super DOT 4 Brake
1 Fluid
I
Materials
Name Specification
ESD-M6C57-A
A WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
handling. If brake fluid contacts the eyes,
flush the eyes for 15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink
8. Using the special tool, bleed the clutch
water and induce vomiting. Get medical system.
attention immediately. Failure to follow
Pump approximately 80 ml of brake fluid into
these instructions may result in personal the clutch svstem. (
injury. w
9. Close the bleed nipple. A CAUTI0N:Y brake fluid is spilt on the
paintwork, the affected area must be 10.
Remove the special tool.
immediately washed down with cold water.
11. Lower the vehicle, if necessary.
N0TE:lf proprietary brake bleeding equipment is
available, this can be used to bleed the clutch
system, following the method below. The maximum
pressure must not exceed
1.5 bar.
N0TE:The clutch control system is self-venting.
The components are arranged in such a way that
small amounts of air trapped in the system are
removed automatically during clutch operation.
12. In order to remove any small amounts of
trapped air remaining in the system,
operate the clutch pedal several times
(maximum five times), using the full clutch
pedal travel.
13. Check the fluid level in the brake fluid
reservoir and top up to the MAX mark with
brake fluid if necessary.
1. Remove the air cleaner, if necessaryfor 14. Install the battery tray, if necessary.
additional information, refer to
Section
303-12 [Intake Air Distribution and 15.
Install the battery, if necessary. For
Filtering]. additional
information, refer to
Section 414-01 [Battery, Mounting and
2. Remove the battery, if necessary. For
Cablesl.
additional information, refer to
Section
414-01 [Battery, Mounting and . 16. Install the air cleaner, if necessary. For
Cables]. additional
information, refer to
Section 303-1
2 [Intake Air Distribution and - 3. Remove the battery tray, if necessary.
Filtering]. (' L 4. Drain the brake fluid reservoir.
17. Test the clutch control system for normal "I-
5. Raise and support the vehicle, if necessary. operation.
For additional information, refer to
Section 100-02 [Jacking and Lifting].
2006.0 Fiesta 1212006 GI 83752en
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Manual Transmission/Transaxle and Clutch -
308-00-1 3 General Information 308-00-1 3
GENERAL PROCEDURES
Start the engine, depress the clutch pedal,
wait two seconds, then carefully engage
reverse gear. If there are any abnormal
noises, or reverse gear is difficult to engage,
repeat the clutch system bleeding procedure.
18. Initialize the door window motors, if
necessary. For additional information, refer
to Section 501-11 [Glass, Frames and
Mechanisms].
2006.0 Fiesta 1212006 GI 83752en
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308-01 -7 Clutch 308-01 -7
REMOVAL AND INSTALLATION
Clutch Disc and Pressure Plate(l6 724 4)
S~ecial Tool(s1 Installation
Removal
I. Remove the transaxle.For additional
information, refer to: (308-03A Manual
Transmission/Transaxle - Vehicles With:
5Speed Manual Transaxle (iB5))
Transaxle - I .6L Duratec-1 6V (Sigma)ll .6L
Duratec-16V Ti-VCT (sigma)- (~'m'val) 9 2. nCAUTION :Tighten the clutch pressure Transaxle - 1.8L Duratec-HE (M14) (Removal). plate retaining bolts finger tight and then
2m &AUTION:LOOS~~ the clutch pressure evenly
by two turns at a time in the sequence
plate retaining bolts by two turns at a time shown
to the specified torque.
in the
sequence shown. N0TE:lnstall new clutch pressure plate retaining I Remove the clutch disc and pressure plate. bolts.
Discard the bolts.
2006.0 Fiesta 121~0o6 G28811 en
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308-01 -8 Clutch 308-01 -8
REMOVAL AND INSTALLATION
Using the special tool, install the clutch disc
and pressure
plate.
3. Remove the special tool.
4. Install the transaxle. For additional
information, refer to: (308-03A Manual
Transmission/Transaxle - Vehicles With:
5-Speed
Manual Transaxle (iB5))
Transaxle - 1.6L Duratec-1 6V (Sigma)ll.GL
Duratec-1 6V Ti-VCT (Sigma) (Installation),
Transaxle - 1.8L Duratec-HE (M14)
(Installation).
2006.0 Fiesta 1212006 ~28811 en
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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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308-02-6 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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