Ford 2002 Bantam - Page 891

308-00-3 Manual Transaxle and Clutch — General Information 308-00-3
DIAGNOSIS AND TESTING
E6760 EN 07/2001 2002 Bantam
Manual Transaxle and Clutch
Special Tool(s)
12 Volt UV Spot Lamp or
equivalent
164-R0751
Inspection and Verification - Clutch
1. Verify the customer concern by operating the
system.
2. Visually inspect for obvious signs of
mechanical or electrical damage.
3. If an obvious cause for an observed or
reported concern is found, correct the cause
(if possible) before proceeding to the next
step.
4. If the concern is not evident, verify the
symptom and refer to the Symptom Chart.
Visual Inspection Chart
Mechanical
• Fluid leaks from the transaxle.
• Visibly damaged or worn parts.
• Loose or missing bolts or nuts.
Inspection and Verification - Manual
Transaxle
The following checks should be carried out
before repairing or installing a new transaxle:
Poor gear shifting
1. Check the operation of the clutch: Lay a
block of wood approximately 25 mm thick
under the clutch pedal and depress the
clutch pedal as far as the stop. If 1st or 2nd
gear can be selected with no problem with
the engine running and the parking brake
applied, the clutch is OK. If the gear cannot
be selected, repair the clutch.
2. Check the selector mechanism:
The free play in the gearshift lever must be no
more than 15 mm.
• If the gearshift lever free play is too great,
check the gearshift cables and install new
cables if necessary.
If the gearshift lever free play is OK, adjust the
gearshift linkage.
REFER to Gearshift Linkage
Adjustment in this section
3. Check the transmission fluid level and top up
with manual transmission fluid BOT 130, if
necessary.
Transaxle noise
If transaxle noise is reported, first check the
transmission fluid level. If damage has occurred
due to a lack of fluid, install a new transaxle.
Fluid leakage
• Check that the leaking fluid is actually
transmission fluid and not hydraulic fluid (from
the hydraulically operated clutch) or engine
oil.
• Check the transmission fluid level and, if
necessary, drain off any excess fluid.
• Locate the oil leak with the aid of a
fluorescent test fluid and an Ultra Violet
inspection lamp.
• Clean the transaxle and the adjacent areas
carefully before the road test.