Symptom Chart- Manual Transmission And Transfer Case Noise/Vibration

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

SYMPTOM CHART - MANUAL TRANSMISSION AND TRANSFER CASE NOISE/VIBRATION

Condition	Possible Sources	Action
Clutch rattling noise - occurs with the clutch engaged, noise changes/disappears with the clutch pedal applied	Flywheel bolts, clutch housing bolts or clutch pressure plate bolts loose	TIGHTEN the bolts to specifications. CHECK the bolts for damage. REFER to CLUTCH .
Clutch squeaking noise - occurs with clutch pedal applied/released	Worn clutch pedal shaft or bushings	INSPECT the clutch pedal for wear or damage. REPAIR as necessary. REFER to CLUTCH CONTROLS .
Clutch whirring/rattle noise - occurs when the clutch pedal is applied	Worn, damaged or misaligned clutch release bearing/slave cylinder	INSTALL a new clutch release bearing/slave cylinder. REFER to CLUTCH CONTROLS .
Clutch grating/grinding noise - occurs when the clutch pedal is applied	Clutch pressure plate fingers bent or worn	INSPECT the clutch pressure plate release fingers. INSTALL a new pressure plate as necessary. REFER to INSTALLATION .
	Contact surface of the clutch release bearing/slave cylinder worn or damaged	INSTALL a new clutch release bearing/slave cylinder. REFER to CLUTCH CONTROLS .
Clutch chatter - a small amount of noise when the clutch pedal is released at initial take-off	Clutch engagement	Acceptable operating condition.
Clutch chatter/grabs - in some cases a shudder is felt. Occurs with the clutch pedal applied/released	Damaged or worn powertrain/driveline mounts	INSPECT the powertrain/drivetrain mounts. REFER to ENGINE - 2.3L . INSTALL new mounts as necessary.
	Binding or dragging plunger of the clutch master cylinder or slave cylinder	CHECK the master and slave cylinder operation. INSPECT the components for damage or wear. INSTALL a new master or slave cylinder as necessary. REFER to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .
	Grease or oil on the clutch disc facing	CHECK the input shaft seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch disc. REFER to INSTALLATION .
	Clutch disc surface glazed or damaged	INSPECT the clutch disc surface for a glazed, hardened or damaged condition. CARRY OUT a disc check. INSTALL a new clutch disc as necessary. REFER to INSTALLATION .
	Damaged or worn clutch pressure plate	INSPECT the clutch pressure plate for wear or damage. INSTALL a new clutch pressure plate as necessary. REFER to INSTALLATION .
	Flywheel surface damaged or glazed	INSPECT the flywheel for damage or wear. CARRY OUT a flywheel runout check. INSTALL a new flywheel as necessary. REFER to INSTALLATION for the 2.3L engine .
Clutch chatter noise - noise when the clutch pedal is released at initial take-off. Clutch is hard to engage and disengage	Clutch pressure plate worn, damaged or not correctly aligned	INSPECT the clutch pressure plate release fingers for uneven wear or burnt clutch components. INSTALL a new pressure plate as necessary. REFER to CLUTCH .
Clutch vibration	Loose flywheel bolts Damaged or loose clutch pressure plate Excessive flywheel runout	GO to PINPOINT TEST J .
Transmission rattling/clattering noise - noise at idle or on light acceleration from a stop. Gear selection is difficult	Gearshift lever joint worn or damaged	INSTALL a new gearshift lever. REFER to INSTALLATION .
	Gearshift lever loose	TIGHTEN the bolts to specification. REFER to MANUAL TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS .
	Gearshift linkage rods worn or damaged	CHECK the linkage bushings for wear. INSTALL new linkage rods as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS .
Transmission rattling/clattering noise - occurs in neutral or in gear, at idle	Incorrect fluid level or fluid quality	VERIFY that the transmission is filled to the correct level and with the specified fluid.
Transmission rattling/clattering noise - noise at idle in neutral	Worn or rough reverse idler gear	CHECK the reverse idler gear. REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Rough running engine, cylinder misfire	CHECK the ignition system. CARRY OUT a cylinder power test. REPAIR as necessary. REFER to ENGINE IGNITION - 2.3L or ENGINE IGNITION - 3.0L (4V) .
	Excessive backlash in gears	CHECK the gear backlash. ADJUST as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Worn countershaft gears	REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission whine - a mild whine at extreme speeds or high rpm	Rotating gears/geartrain	Acceptable noise.
Transmission whine - a high pitched whine, also described as a squeal	Transmission gears are worn (high mileage vehicle)	Result of normal gear wear. REPAIR as necessary.
	Mismatched gear sets	INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Damaged or worn transmission bearing(s)	INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission growling/humming - noise occurs in the forward gears. The noise is more prominent when the gear is loaded. The problem gear can be located as the noise occurs in a specific gear position	Gear is cracked, chipped or rough	INSPECT the transmission gears for damage or wear. INSTALL new gears as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission hissing - noise in neutral or in forward gears. As bearings wear or break up, the noise changes to a thumping noise	Damaged or worn bearings	INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission knocking/thudding - noise at low speeds in forward gears	Bearings with damaged balls or rollers or with pitted and spalled races	INSPECT the transmission bearings. INSTALL new bearings as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission rumble/growl - noise at higher speeds in forward gears, more pronounced in a coast/deceleration condition	Incorrect driveline angle	CHECK the driveline angle. REPAIR as necessary. REFER to DRIVELINE SYSTEM-GENERAL INFORMATION .
	Driveshaft out of balance or damaged	CHECK the driveshaft for damage, missing balance weights or undercoating. Using the vibration analyzer (VA), CHECK the driveshaft balance. CARRY OUT a driveline vibration test. For additional information, REFER to DRIVESHAFT . REPAIR as necessary.
Transmission rumble/growl - noise at all speeds in forward gears, more pronounced in a heavy acceleration condition	Damaged or worn transmission bearing or gears (high mileage vehicles)	CHECK the transmission fluid for excessive metal particles. REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transfer case whine - noise at all ranges	Incorrect fluid level or fluid quality	VERIFY that the transfer case is filled to the correct level and with the specified fluid. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
	Worn oil pump	DISASSEMBLE the transfer case. CHECK the oil pump for wear or damage. REPAIR as necessary. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
	Under-inflated or oversized tires	CONFIRM that the tires and wheels are correct for the vehicle. CHECK that the tire inflation pressures are correct.
Transfer case growl/rumble - noise at all ranges	Damaged or worn bearings or gears	DISASSEMBLE the transfer case. CHECK the bearings or gears for wear or damage. REPAIR as necessary. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
Transfer case scraping/grating - noise at all ranges	Excessively stretched drive chain hitting the case	DISASSEMBLE the transfer case. CHECK the drive chain for wear or damage. REPAIR as necessary. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
Transfer case howl/hum - noise at all ranges or high range only	Worn or damaged sun (input) gear, clutch pack (intermediate) gear or output shaft gear	CHECK the gears for wear or damage. REPAIR as necessary. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
Transfer case howl/hum - noise at low range only	Worn or damaged intermediate gear and sliding gears (clutch pack)	CHECK the gears for wear or damage. REPAIR as necessary. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
Transfer case vibration - vibration felt with vehicle in 4WD	Transfer case mounting Driveshaft out of balance Excessive pinion flange runout	GO to PINPOINT TEST K .