LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 16 (Manual Transmission & Clutch - General Information) >> Diagnostic Tests >> Manual Transmission and Clutch >> Pinpoint Tests >> Pinpoint Test D: Clutch Drag, Also Hard to Shift >> Pinpoint Test D: Clutch Drag, Also Hard To Shift

Pinpoint Test D: Clutch Drag, Also Hard To Shift

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. D1 CHECK FLUID LEVEL 
    • Key in OFF position.
    • Remove the reservoir cap.
    • Inspect the fluid level in the brake and clutch reservoir.
    • Is the fluid level at or above the step mark? 
    1. YES  : INSTALL the reservoir cap. Go to  D2 .
    2. NO  : ADD brake fluid. Go to  D2 and CHECK for leaks. TEST the system for normal operation.
  2. D2 INSPECT THE CLUTCH HYDRAULIC SYSTEM FOR LEAKAGE 
    • Inspect the clutch master cylinder and the hydraulic lines for leakage.
    • Inspect the reservoir and reservoir line for leakage.
    • Inspect the clutch slave cylinder and the hydraulic line connection for leakage.
    • Are there any signs of leakage? 
    1. YES  : INSTALL new components as necessary. TEST the system for normal operation.
    2. NO  : Go to  D3.
  3. D3 CHECK INTERNAL OPERATION 
    • Remove the reservoir cap.
    • Have an assistant slowly depress 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)? 
    1. YES  : INSTALL a new cylinder master cylinder assembly.
    2. NO  : Go to  D4.
  4. D4 CHECK THE CLUTCH PEDAL RESERVE 
    NOTE: The clutch reserve is the distance between the clutch pedal when fully depressed 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.
      • Fig 1: Identifying Cable Tie To Clutch Pedal
      GF0015713Courtesy of FORD MOTOR CO.
    • Attach a cable tie to the lower clutch pedal.
    • Attach a tape measure to the cable tie.
    • Depress the clutch fully and start the vehicle.
      • Fig 2: Shifting Transmission Into 1St Gear
      GF0015714Courtesy of FORD MOTOR CO.
    • Shift the transmission into 1st gear.
      • Fig 3: Identifying Steering Wheel Reference Point
      GF0015715Courtesy of FORD MOTOR CO.
    • Use the seam on the steering wheel as a reference point.
      • Fig 4: Engaging Clutch While Observing Tape Measure
      GF0015716Courtesy of FORD MOTOR CO.
    • While observing the tape measure, slowly engage the clutch, noting when the vehicle starts to move forward.
    • Is the clutch pedal reserve greater than or equal to 25 mm (1 in)? 
    1. YES  : The clutch hydraulic system is OK. TEST the system for normal operation.
    2. NO  : Go to  D5.
  5. 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.
    • Engine OFF.
    • Attach a tape measure to the cable tie.
      • Fig 5: Checking Clutch Pedal Free Play
      GF0015717Courtesy of FORD MOTOR CO.
    • While observing the tape measure, slowly push downward on the clutch pedal until a slight resistance is felt.
    • Is the clutch pedal free play less than 13 mm (0.5 in)? 
    1. YES  : The clutch hydraulic system is OK. TEST the system for normal operation.
    2. NO  : Go to  D6.
  6. 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? 
    1. YES  : INSTALL a new clutch pressure plate. REFER to CLUTCH .
    2. NO  : Go to  D7.
  7. D7 INSPECT THE CLUTCH DISC 
    NOTE: Vehicles equipped with a 4.0L engine use an inner floating damper design disc. When inspecting the disc, a rattle type noise can be heard. This is a normal operation.
    1. YES  : Go to  D8.
    2. NO  : INSTALL a new clutch disc. REFER to CLUTCH . TEST the system for normal operation.
  8. D8 INSPECT THE TRANSMISSION 
    • Remove the transmission.
    • Disassemble the transmission.
    • 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.
      • 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? 
    1. YES  : INSTALL new components or REPAIR as necessary. TEST the system for normal operation.
    2. NO  : ASSEMBLE and INSTALL the transmission. TEST the system for normal operation.
scientia non olet · About LEMON Manuals