Symptom Chart

WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Symptom Chart - Manual Transmission And Clutch

Condition	Possible Sources	Action
Clutch slippage	Clutch pedal sticking Pressure plate diaphragm spring damaged or weakened Clutch pressure plate damaged Clutch disc facing damaged or worn excessively Clutch disc facing surface hardened or oil coated Clutch release hub and bearing binding Flywheel glazed or damaged	Go to Pinpoint Test A .
Clutch chatter or shudder	Loose or worn engine mount Oil on clutch disc facing Clutch pressure plate damaged or excessive runout Clutch disc facing surface hardened or damaged Flywheel surface glazed or damaged Transmission input shaft eccentric or not perpendicular Pilot bearing worn or damaged	Go to Pinpoint Test B .
Clutch pedal feels spongy or has excessive travel. Clutch will not disengage	Insufficient clutch system fluid Leakage of clutch system fluid Air in the hydraulic system	Go to Pinpoint Test C .
Clutch drag, also hard to shift	Insufficient clutch system fluid Leakage of clutch system fluid Excessive runout or damaged clutch disc Clutch disc splines rusted or worn Pilot bearing worn or damaged	Go to Pinpoint Test D .
Clutch pedal pulsation	Clutch disc damaged or worn Excessive flywheel runout	Go to Pinpoint Test E .
Clutch related vibrations	Engine component grounding against frame Loose flywheel bolts Excessive flywheel runout Imbalanced clutch pressure plate Accessory drive belt loose or damaged Pilot bearing worn or damaged	Go to Pinpoint Test F .
Binding - difficult shift lever movement	Insufficient clutch system fluid Damaged clutch slave cylinder Transmission concern	Go to Pinpoint Test G .
Excessive noise	Clutch slave cylinder Pilot bearing worn or damaged Excessive crankshaft end play Clutch pressure plate or disc	Go to Pinpoint Test H .
Transmission difficult to shift - grinding noise when shifting	Insufficient clutch hydraulic fluid	ADD specified lubricant.
	Internal shift mechanism	CHECK internal shift mechanism for smooth operation. REPAIR or INSTALL a new component as required.
	Sliding gears and/or synchronizers	CHECK for free movement of gears and synchronizers. REPAIR or INSTALL a new component as required.
	Housings and/or shafts	CHECK for binding condition between input shaft and engine crankshaft pilot bearing or bushing. REPAIR or INSTALL new components as required. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Air in clutch hydraulic system	Go to Pinpoint Test C .
NOTE: While verifying the condition, determine whether the noise is gear roll-over noise, release bearing rub or some other transmission-related noise. Gear roll-over noise, inherent in manual transmission, is caused by the constant mesh gears turning at engine idle speed while the clutch is engaged and the transmission is in NEUTRAL. Release bearing rub is sometimes mistaken for mainshaft bearing noise. Gear roll-over noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Release bearing rub will disappear when the clutch is engaged. In the event that a bearing is damaged, the noise is more pronounced while engaged in gear under load or coast than in NEUTRAL. Noisy in forward gears	Lubricant level low/incorrect type	ADD or REFILL with the specified lubricant. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Components grounding out on transmission	CHECK for screws, bolts, etc., of cab or other components grounding out. CORRECT as necessary.
	Bolts retaining transmission to engine loose	VERIFY that the bolts are tightened to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Bearings/gears worn/damaged	INSPECT the bearings, the gears and the gear teeth for wear and damage. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
Gears clash when shifting from one forward gear to another	Transmission input shaft pilot bearing worn/damaged	INSPECT the transmission input shaft pilot bearing for wear and damage. REPAIR as necessary.
	Gear teeth/synchronizer damaged	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Engine idle speed too high	REFER to the INTRODUCTION - GASOLINE ENGINES article.
Transmission jumps out of gear	Gearshift lever boot installed incorrectly	CHECK gearshift lever boot installation. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Bolts retaining transmission to engine loose	TIGHTEN the bolts to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Transmission input shaft pilot bearing	INSTALL a new transmission input shaft pilot bearing. REFER to CLUTCH article.
	Axial clearance incorrect Internal components damaged	CHECK axial clearance. INSPECT the synchronizer sleeves for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surface. CHECK the countershaft cluster gear for excessive end play. INSPECT the shift forks for wear. CHECK for loose shift forks on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear and damage. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Gear teeth worn/damaged	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
Transmission will not shift into one gear - all others OK	Internal components	For the gear in question, INSPECT the shift rail and fork, the synchronizer and the gear clutch teeth for restricted travel. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
Transmission is locked in one gear and will not shift out of that gear	Internal components	INSPECT the gears, the shift rails and the forks and the synchronizer for wear and damage. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
Fluid leaks	Engine, power steering, transmission, clutch	REMOVE all traces of lubricant on the exposed transmission surfaces. VERIFY that the transmission vent is clear of foreign material. OPERATE the transmission. INSPECT for new leakage. REFER to the appropriate section for repair procedures. REFER to POWER STEERING article, ENGINE - 4.2L article, ENGINE - 4.6L (2V) article, ENGINE - 5.4L (3V) article, CLUTCH CONTROLS article or MANUAL TRANSAXLE/TRANSMISSION article.
	Input shaft bearing retainer seal	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Shift rail detent plug	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Top cover gasket	INSPECT and REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Power take-off (PTO) cover	INSPECT and REPAIR as necessary. INSTALL a new gasket. TIGHTEN to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Sand holes/cracks in case	INSPECT and INSTALL a new case as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Fill and drain plugs	INSPECT the plug, the O-ring and the threads in the case. REPAIR as necessary. TIGHTEN the plug to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION article.

Symptom Chart - Bearing Failure Concerns

Condition	Possible Sources	Action
Bearing failure	Raceways or rollers worn or damaged will occur by towing a vehicle further than 80 km (50 miles) with driveshaft installed. Mainshaft tapered bearing and needle caged bearings are especially susceptible to damage	REMOVE, DISASSEMBLE and CLEAN the transmission; then INSTALL new components as required. (Necessary to RESET bearing preload if any tapered bearings are installed.) REFER to MANUAL TRANSAXLE/TRANSMISSION article.
	Input shaft oil dam	DETERMINE cause of vibration and CORRECT. Otherwise PROCEED as above. INSTALL new components and make sure of correct oil dam installation. REFER to MANUAL TRANSAXLE/TRANSMISSION article. CHECK for correct installation of the snap ring on the mainshaft next to the oil dam.
	Oil baffle in the input bearing shim pack	INSTALL new components making sure the oil baffle is not damaged during reassembly. REFER to MANUAL TRANSAXLE/TRANSMISSION article.