Pinpoint Test D: Clutch Drag, Also Hard To Shift

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

D1 CHECK FLUID LEVEL
- Ignition OFF.
- Remove the reservoir cap.
- Inspect the fluid level in the brake and clutch reservoir.
- Is the fluid level at or above the step mark?
- Yes : INSTALL the reservoir cap. GO to D2.
- No : ADD brake fluid. GO to D2 and CHECK for leaks.
D2 INSPECT THE CLUTCH HYDRAULIC SYSTEM FOR LEAKAGE
- Inspect the clutch master cylinder and the hydraulic tubes for leakage.
- Inspect the reservoir and reservoir tube for leakage.
- Inspect the clutch slave cylinder and the hydraulic tube connection for leakage.
- Are there any signs of leakage?
- Yes : INSTALL new components as necessary.
- No : GO to D3.
D3 CHECK INTERNAL OPERATION
- Remove the reservoir cap.
- Have an assistant slowly apply and release the clutch pedal.
- On the down stroke, the fluid level should not increase by more than 1 mm (0.039 in).
- Does the fluid level increase more than 1 mm (0.039 in)?
- Yes : INSTALL a new clutch master cylinder assembly. REFER to CLUTCH CONTROLS .
- No : GO to D4.
D4 CHECK THE CLUTCH PEDAL RESERVE
NOTE: The clutch reserve is the distance between the clutch pedal when fully applied and the position when the vehicle starts to move forward.
- Park the vehicle on a level surface.
- Check for obstructions behind the clutch pedal. Check the carpet for correct installation. Remove the floor mat.
- Attach a cable tie to the lower clutch pedal.
  
  Fig 1: Attaching Cable Tie To Clutch Pedal
  Courtesy of FORD MOTOR CO.
- Attach a tape measure to the cable tie.
- Apply the clutch fully and start the vehicle.
- Shift the transmission into 1st gear.
  
  Fig 2: Shifting Transmission Into 1st Gear
  Courtesy of FORD MOTOR CO.
- Use the seam on the steering wheel as a reference point.
  
  Fig 3: Making Reference Point On Steering Wheel
  Courtesy of FORD MOTOR CO.
- While observing the tape measure, slowly engage the clutch, noting when the vehicle starts to move forward or a noticeable engine RPM decrease occurs (noted on tachometer).
  
  Fig 4: Checking Clutch Pedal Reserve
  Courtesy of FORD MOTOR CO.
- Is the clutch pedal reserve greater than or equal to 25 mm (0.984 in)?
- Yes : The clutch hydraulic system is OK.
- No : GO to D5.
D5 CHECK THE CLUTCH PEDAL FREE PLAY
NOTE: The clutch pedal free play is the distance between the clutch pedal when fully released and the position when slight resistance is felt on downward motion.
- Ignition OFF.
- Attach a tape measure to the cable tie.
- While observing the tape measure, slowly push downward on the clutch pedal until a slight resistance is felt.
  
  Fig 5: Checking Clutch Pedal Free Play
  Courtesy of FORD MOTOR CO.
- Is the clutch pedal free play less than 13 mm (0.511 in)?
- Yes : The clutch hydraulic system is OK.
- No : GO to D6.
D6 CHECK THE CLUTCH PRESSURE PLATE
- Remove the clutch pressure plate. REFER to CLUTCH .
- Inspect the clutch pressure plate for wear or runout. REFER to CLUTCH PRESSURE PLATE CHECK .
- Are there any signs of excessive wear or runout to the clutch pressure plate?
- Yes : INSTALL a new clutch pressure plate. REFER to CLUTCH .
- No : GO to D7.
D7 INSPECT THE CLUTCH DISC
- Carry out the CLUTCH DISC INSPECTION procedure.
- Is the clutch disc OK?
- Yes : GO to D8.
- No : INSTALL a new clutch disc. REFER to CLUTCH .
D8 INSPECT THE TRANSMISSION
- Remove the transmission. REFER to MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED or MANUAL TRANSAXLE/TRANSMISSION - TR6060 .
- Disassemble the transmission. REFER to MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED or MANUAL TRANSAXLE/TRANSMISSION - TR6060 .
- Carry out the following:
  - Inspect all the shift rails for excessive scuffing or wear.
  - Check the interlock pins on the shift rail.
  - Make sure the interlock bolts are tightened to specifications. REFER to MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED or MANUAL TRANSAXLE/TRANSMISSION - TR6060 .
  - Inspect the shift pads for wear or cracking.
  - Inspect the shift forks for wear or damage.
  - Check the synchronizer rings of the affected gear for wear or damage.
  - Check the synchronizer hubs of the affected gear for wear or damage.
  - Inspect the clutching teeth of the affected gear.
- Are there any internal components worn or damaged?
- Yes : INSTALL new components or REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED or MANUAL TRANSAXLE/TRANSMISSION - TR6060 .
- No : ASSEMBLE and INSTALL the transmission. REFER to MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED or MANUAL TRANSAXLE/TRANSMISSION - TR6060 .