Symptom Chart

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

SYMPTOM CHART

Condition	Possible Sources	Action
Clutch slippage	Insufficient clutch pedal play. Clutch pedal sticking. Pressure plate diaphragm spring damaged or weakened. Clutch pressure plate damaged. Clutch disc facing excessively worn. Clutch disc facing surface hardened or oil coated. 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.	GO to PINPOINT TEST B .
Clutch drag	Insufficient fluid. Leakage of fluid. Excessive clutch pedal free play. Excessive runout or damaged clutch disc. Clutch disc splines rusted or worn. Sand/dust contamination in the clutch mechanism.	GO to PINPOINT TEST C .
Clutch pedal pulsation	Clutch pedal pivot point not correctly lubricated. Excessive flywheel runout.	GO to PINPOINT TEST D .
Clutch related vibrations	Engine component grounding against frame. Loose flywheel bolts. Excessive flywheel runout. Imbalanced clutch pressure plate.	GO to PINPOINT TEST E .
Hard shifting	Insufficient fluid. Excessive clutch pedal free play. Damaged or worn gear shifter fork. Damaged clutch slave cylinder. Manual transaxle concern. Contamination of the clutch.	GO to PINPOINT TEST F .
Excessive noise	Insufficient clutch pedal free play. Damaged clutch slave cylinder. Poor lubrication of release bearing sleeve. Bearing worn or damaged. Excessive crankshaft end play.	GO to PINPOINT TEST G .
Transmission difficult to shift - grinding noise when shifting	Insufficient clutch hydraulic fluid.	ADD specified lubricant.
	Internal shift mechanism.	CHECK the internal shift mechanism for smooth operation. REPAIR or INSTALL new components as required.
	Sliding gears and/or synchronizers.	CHECK for free movement of gears and synchronizers. REPAIR or INSTALL new components as required.
	Air in clutch hydraulic system.	GO to PINPOINT TEST C .
NOTE: While verifying the condition, determine whether the noise is a gear roll over noise, release bearing rub or some other transmission-related noise. Gear roll over noise is caused by the constant mesh gears turning at the engine idle speed while the clutch is engaged and the transmission is in NEUTRAL. Gear roll over noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Release bearing rub is sometimes mistaken for mainshaft bearing noise. 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.	ADD specified lubricant as necessary.
	Components grounding out on the transmission.	CHECK for screws, bolts or other components grounding out. CORRECT as required.
	Component housing bolts.	CHECK the torque on the transmission-to-clutch housing bolts and the clutch housing-to-engine block bolts. TIGHTEN the bolts to specification. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Bearings or gears.	INSPECT the bearings. INSPECT the gears and gear teeth for wear or damage. INSTALL new components as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Gears clash when shifting from one forward gear to another	Gear teeth and/or synchronizer.	REPAIR or INSTALL new components as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Gears clash when shifting from one forward gear to another	Engine idle speed too high.	REFER to the INTRODUCTION - GASOLINE .
Transmission jumps out of gear	Excessive gearshift lever boot tension.	INSTALL a new gearshift lever boot and knob assembly. REFER to MANUAL TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS .
	Transmission-to-engine mounting bolts.	TIGHTEN the transmission-to-engine block bolts to specification. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Internal components.	INSPECT the synchronizer sleeves for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and a smooth internal surface. CHECK the countershaft cluster gear for excessive end play. CHECK the shift forks for worn or loose mounting on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear or damage. REPAIR or INSTALL new components as necessary.
	Gear teeth worn or damaged.	INSTALL new gears. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission will not shift into one gear - all others OK	Manual shifting linkage.	REPAIR or INSTALL new components as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION EXTERNAL CONTROLS .
	Reversing lamp switch ball.	If REVERSE is the problem, CHECK the reversing lamp switch for the ball frozen in the extended position.
	Internal components.	INSPECT the shift rail and fork system, the synchronizer system and the gear clutch teeth for restricted travel. REPAIR or INSTALL new components as necessary.
Transmission is locked in one gear and cannot be shifted out of that gear	Internal components.	INSPECT the problem gears, the shift rails, the forks and the synchronizer for wear or damage. REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Fork on rail.	CHECK the shift rail interlock system. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Transmission leaks	Lubricant.	CHECK the fluid level and type.
	Other components leaking.	IDENTIFY the leaking fluid as engine, power steering, or transmission fluid. REPAIR as required. REMOVE all traces of fluid on exposed transmission surfaces. CHECK the vent for free breathing. OPERATE the transmission and INSPECT for new leakage. REPAIR as necessary.
	Internal components.	INSPECT for leaks at the input shaft bearing retainer seal and the shift rail expansion plug. REFER to MANUAL TRANSAXLE-TRANSMISSION . INSPECT for leaks at the transaxle case-to-clutch housing seam. INSPECT the case for sand holes or cracks. REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Fill and drain plugs.	CHECK the fill plug, the drain plug, and the bore threads. REPAIR as necessary. TIGHTEN to specification. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Transmission case bolt.	CHECK for loose or missing bolts. REPAIR as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Halfshaft oil seals.	CHECK for cracked, loose or damaged RH intermediate shaft oil seal or LH halfshaft oil seal. REPLACE as necessary. REFER to MANUAL TRANSAXLE-TRANSMISSION .
Noise from transfer case	Tire and wheels.	MAKE sure that all tires and wheels are the same size and that the inflation pressures are correct.
	Tire tread.	DETERMINE if there is more than 1.5 mm (0.06 inch) difference in the tread wear between the front and rear tires.
	Internal components.	INSTALL new components as necessary. REFER to TRANSFER CASE-POWER TRANSFER UNIT (PTU) .
Bearing failure	Other part failure. Raceways or rollers. Lubricant.	REMOVE, DISASSEMBLE, and CLEAN the transmission, then REPLACE the damaged parts. (It is necessary to RESET the bearing preload if any tapered bearings are replaced). REFER to MANUAL TRANSAXLE-TRANSMISSION .
	Vibration break-up of retainer and brinelling of races. Bearing(s). Shafts or bore. Overloading of vehicle. Incorrect preload.	DETERMINE and CORRECT the cause of the vibration. Otherwise, PROCEED as above.
	Input shaft oil dam.	INSTALL new components and verify correct oil dam installation. REFER to MANUAL TRANSAXLE-TRANSMISSION . 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. MAKE SURE the oil baffle is not damaged during reassembly. REFER to MANUAL TRANSAXLE-TRANSMISSION .