Symptom Chart: Manual Transmission
WARNING: This page is about a different variant/trim than selected.
Diagnostics in this article assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods
| Symptom | Possible Sources | Action |
|---|---|---|
| Transmission difficult to shift when cold | Normal Condition | Excessive force to select gears when the transmission is cold is a normal condition. Test drive the vehicle to see if the condition is still present when it warms up. |
| Transmission difficult to shift | Lubricant | ADD or DRAIN and FILL with specified lubricant. REFER to: Transmission Draining and Filling |
| Internal shift mechanism | CHECK the internal shift mechanism for smooth operation. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Sliding gears, synchronizers | CHECK for free movement of gears and synchronizers. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Housings, shaft | CHECK for binding condition between the input shaft and the pilot bearing. REPAIR or INSTALL new components as necessary. REFER to: Variable Camshaft Timing (VCT) Oil Control Solenoid | |
| Loose pressure plate to flywheel bolts | CHECK for loose bolts at the pressure plate. REPAIR or INSTALL new components as necessary. REFER to: Clutch Disc and Pressure Plate - 5.0L 32V Ti-VCT | |
| Transmission will not shift -- gearshift lever moves | Gearshift lever damaged | INSTALL a new gearshift lever. REFER to: Gearshift Lever |
| Damaged or worn selector arm. Loose shift rail bushings | CHECK the internal shift components. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Damaged or offset lever plate | CHECK the internal shift components. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
|
NOTE:
While verifying the condition, determine whether the noise is gear rollover noise, release bearing rub or some other transmission-related noise. Gear rollover noise, inherent in manual transmissions, is caused by the constant mesh of gears turning at the 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 rollover 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 | ADD or DRAIN and FILL with specified lubricant. REFER to: Transmission Draining and Filling |
| Components grounding out on the transmission | CHECK for screws and bolts of body or other components grounding out. CORRECT as necessary. | |
| Components housing bolts | CHECK the torque on the transmission-to-flywheel housing bolts and the flywheel housing-to-engine block bolts. TIGHTEN the bolts to specification. | |
| Bearings or gears | INSPECT the bearings. INSPECT the gears and gear teeth for wear or damage. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Axle howl or whine | The 3160 transmission may be suspect of a gear whine noise, which seems to be emanating from the rear of the vehicle at or in excess of 80 km/h (50 mph) at full operating temperature. Drive the vehicle at customer complaint speeds in 5th gear (this is the direct gear) to eliminate manual transmission as noise source, reach full operating temperature and confirm if noise is still present. REFER to: Suspension System | |
| Gears clash when shifting from one forward gear to another | Pilot bearing | CHECK for a binding condition between the input shaft and the pilot bearing. REPAIR or INSTALL new components as necessary. REFER to: Variable Camshaft Timing (VCT) Oil Control Solenoid |
| Gear teeth and/or synchronizer | REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Damaged shift forks or worn shift fork inserts | INSPECT for wear or damage. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Transmission jumps out of gear | Transmission-to-engine mounting bolts | TIGHTEN the bolts to specification. |
| Crankshaft pilot bearing | INSTALL a new flywheel. REFER to: Variable Camshaft Timing (VCT) Oil Control Solenoid | |
| Internal Damage | 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 shift forks for worn or loose mounting on shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear or damage. Install a new transmission as necessary. REFER to: Transmission | |
| Gear teeth | If worn or damaged, INSTALL new gears. REFER to: Transmission | |
| Transmission will not shift into one gear -- all others OK | Manual shift linkage | REPAIR or INSTALL new components as necessary. |
| Backup switch ball | If REVERSE is the problem, CHECK reverse lamp switch for ball frozen in extended position. | |
| Internal components | INSPECT the shift rail and fork system, synchronizer system and the gear clutch teeth for restricted travel. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Transmission is locked in one gear and cannot be shifted out of that gear | Internal components | INSPECT the problem gears, shift rails, forks and the synchronizer for wear or damage. Install a new transmission as necessary. REFER to: Transmission |
| Fork on rail or shift rail | CHECK the shift rail interlock system. REPAIR or INSTALL new components as necessary. REFER to: Transmission | |
| Transmission leaks | Lubricant | CHECK the level and type. REFER to: Transmission Fluid Level Check |
| Other component leaking | IDENTIFY leaking fluid as engine, power steering or transmission fluid. REPAIR as necessary. | |
| False report | REMOVE all traces of lube on the 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 seal. INSPECT the case for sand holes or cracks. REPAIR or INSTALL a new case as necessary. | |
| Fill and drain plugs | CHECK fill and drain plugs and bore threads. REPAIR as necessary. TIGHTEN plugs to specified torque value. | |
| Bearing failure | Other part failure Raceways or rollers Lubricant Towing vehicle further than 80 km (50 mi) with driveshaft installed. |
REMOVE, DISASSEMBLE and CLEAN the transmission. Inspect for damaged parts and install new components as necessary. REPAIR or INSTALL new components as necessary. REFER to: Transmission |
| Vibration break-up of retainer and brinelling of races Bearing(s) Shafts or bore Incorrect preload |
REPAIR or INSTALL new components as necessary. REFER to: Transmission | |