Ford Festiva. Manual — part 60
VACUUM PUMP - DIESEL TROUBLE SHOOTING
VACUUM PUMP (DIESEL) TROUBLE SHOOTING CHART
MANUAL TRANSMISSION
MANUAL TRANSMISSION TROUBLE SHOOTING
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING
Clogged air bleeds
Remove restriction
EGR valve malfunction
Replace EGR valve
Restricted air cleaner filter
Replace air filter
Cracked or broken vacuum hoses
Replace vacuum hoses
Cracked or broken ignition wires
Replace ignition wires
Vacuum advance malfunction
Check unit and replace as
necessary
Defective or fouled spark plugs
Replace spark plugs
Ping or Spark Knock
Incorrect ignition timing
Reset ignition timing see
ENGINE PERFORMANCE
Distributor centrifugal or vacuum advance malfunction
Check operation and replace
as necessary
Carburetor setting too lean
Readjust mixture setting, see
ENGINE PERFORMANCE
Vacuum leak
Eliminate vacuum leak
EGR valve malfunction
Replace EGR valve
Poor Gasoline Mileage
Cracked or broken vacuum
Replace vacuum hoses hoses
Vacuum leaks
Repair vacuum leaks
Defective ignition wires
Replace wires
Incorrect choke setting
Readjust setting, see ENGINE
PERFORMANCE
Defective vacuum advance
Replace vacuum advance
Defective spark plugs
Replace spark plugs
Binding carburetor power piston
Eliminate binding
Dirt in carburetor jets
Clean and/or replace jets
Incorrect float adjustment
Readjust float setting, see
FUEL
Defective power valve
Replace power valve, see
ENGINE PERFORMANCE
Incorrect idle speed
Readjust idle speed
Engine Stalls
Improper float level
Readjust float level
Leaking needle valve and seat
Replace needle valve and seat
Vacuum leaks
Eliminate vacuum leaks
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list
of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT,
DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.
NOTE:
Diesel engines mechanical diagnosis is the same as gasoline engines for items such as noisy valves,
bearings, pistons, etc. The following trouble shooting covers only items pertaining to diesel engines.
CONDITION & POSSIBLE CAUSE
CORRECTION
Excessive Noise
Loose pump-to-drive assembly screws
Tighten screws
Loose tube on pump assembly
Tighten tube
Valves not functioning properly
Replace valves
Oil Leakage
Loose end plug
Tighten end plug
Bad seal crimp
Remove and re-crimp
seal
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list
of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT,
DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.
Condition
Possible Cause
Noisy In Forward Gears
Low gear oil level, Loose bell housing bolts, Worn bearings or
gears
Clunk On Deceleration (FWD Only)
Loose engine mounts, Worn inboard CV joints, Worn differential
pinion shaft, Side gear hub counterbore in case worn oversize
POWERTRAIN
CLUTCH TROUBLE SHOOTING
BASIC CLUTCH TROUBLE SHOOTING CHART
Gear Clash When Shifting Forward Gears
Clutch Out Of Adjustment, Shift linkage damaged or out of
adjustment, Gears or synchronizers damaged, Low gear oil level
Transmission Noisy When Moving (RWD Only) Quiet In Neutral
With Clutch Engaged
Worn rear outputshaft bearing
Gear Rattle
Worn bearings, Wrong gear oil, Low gear oil, Worn gears
Steady Ticking At Idle (Increases With RPM)
Broken tooth on gear
Gear Clash When Shifting Forward Gears
Worn or broken synchronizers
Loud Whine In Reverse
Normal condition
(1)
Noise When Stepping On Clutch
Bad release bearing, Worn pilot bearing
Ticking Or Screeching As Clutch Is Engaged
Faulty release bearing, Uneven pressure plate fingers
Click Or Snap When Clutch Is Engaged
Worn clutch fork, Worn or broken front bearing retainer
Transmission Shifts Hard
Clutch not releasing, Shift mechanism binding, Clutch installed
backwards
Will Not Shift Into One Gear, Shifts Into All Others
Bent shift fork, Worn detent balls
Locked Into Gear, Cannot Shift
Clutch adjustment, Worn detent balls
Transmission Jumps Out Of Gear
Pilot bearing worn, Bent shift fork, Worn gear teeth or face,
Excessive gear train end play, Worn synchronizers, Missing detent
ball spring, Shift mechanism worn or out of adjustment, Engine or
transmission mount bolts loose or out of adjustment, Transmission
not aligned
Shift Lever Rattle
Worn shift lever or detents, Worn shift forks, Worn synchronizers
sleeve
Shift Lever Hops Under Acceleration
Worn engine or transmission mounts
(1)
Most units use spur cut gears in reverse and are noisy
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list
of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT,
DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSE
CORRECTION
Chattering or Grabbing
Incorrect clutch adjustment
Adjust clutch
Oil, grease or glaze on facings
Disassemble and clean or replace
Loose "U" joint flange
See DRIVE AXLES article
Worn input shaft spline
Replace input shaft
Binding pressure plate
Replace pressure plate
Binding release lever
See CLUTCH article
Binding clutch disc hub
Replace clutch disc
Unequal pressure plate contact
Replace worn/misaligned
components
Loose/bent clutch disc
Replace clutch disc
Incorrect transmission alignment
Realign transmission
Worn pressure plate, disc or flywheel
Replace damaged components
Broken or weak pressure springs
Replace pressure plate
Sticking clutch pedal
Lubricate clutch pedal & linkage
Incorrect clutch disc facing
Replace clutch disc
Engine loose in chassis
Tighten all mounting bolts
Failure to Release
Oil or grease on clutch facings
Clean or replace clutch clutch
disc
Incorrect release lever or pedal adjustment
See CLUTCH article
Worn or broken clutch facings
Replace clutch disc
Bent clutch disc or pressure plate
Replace damaged components
Clutch disc hub binding on input shaft
Clean or replace clutch disc
and/or input shaft
Binding pilot bearing
Replace pilot bearing
Sticking release bearing sleeve
Replace release bearing and/or
sleeve
Binding clutch cable
See CLUTCH article
Defective clutch master
Replace master cylinder
Defective clutch slave
Replace slave cylinder
Air in hydraulic system
Bleed hydraulic system
Rattling
Weak or broken release lever spring
Replace spring and check
alignment
Damaged pressure plate
Replace pressure plate
DRIVE AXLE - NOISE DIAGNOSIS
Unrelated Noises
Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. Ensure
cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires,
CV/universal joints and wheel trim rings.
In certain conditions, the pitch of the exhaust gases may e gear whine. At other times, it may be mistaken for a wheel bearing rumble.
Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some non-standard tires with an
unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.
Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing the noise before disassembling
the drive axle.
Gear Noise
Broken clutch return spring
Replace return spring
Worn splines on clutch disc or input shaft
Replace clutch disc and/or input
shaft
Worn clutch release bearing
Replace release bearing
Dry or worn pilot bearing
Lubricate or replace pilot bearing
Unequal release lever contact
Align or replace release lever
Incorrect pedal free play
Adjust free play
Warped or damaged clutch disc
Replace damaged components
Slipping
Pressure springs worn or
Release pressure plate
Oily, greasy or worn facings
Clean or replace clutch disc
Incorrect clutch alignment
Realign clutch assembly
Warped clutch disc or pressure plate
Replace damaged components
Binding release levers or clutch pedal
Lubricate and/or replace release
components
Squeaking
Worn or damaged release
Replace release bearing
Dry or worn pilot or release bearing
Lubricate or replace assembly
Pilot bearing turning in crankshaft
Replace pilot bearing and/or
crankshaft
Worn input shaft bearing
Replace bearing and seal
Incorrect transmission alignment
Realign transmission
Dry release fork between pivot
Lubricate release fork and pivot
Heavy and/or Stiff Pedal
Sticking release bearing sleeve
Replace release bearing and/or
sleeve
Dry or binding clutch pedal hub
Lubricate and align components
Floor mat interference with pedal
Lay mat flat in proper area
Dry or binding ball/fork pivots
Lubricate and align components
Faulty clutch cable
Replace clutch cable
Noisy Clutch Pedal
Faulty interlock switch
Replace interlock switch
Self-adjuster ratchet noise
Lubricate or replace self-adjuster
Speed control interlock switch
Lubricate or replace interlock
switch
Clutch Pedal Sticks Down
Binding clutch cable
See CLUTCH article
Springs weak in pressure plate
Replace pressure plate
Binding in clutch linkage
Lubricate and free linkage
Noisy
Dry release bearing
Lubricate or replace release
bearing
Dry or worn pilot bearing
Lubricate or replace bearing
Worn input shaft bearing
Replace bearing
Transmission Click
Weak springs in pressure
Replace pressure plate plate
Release fork loose on ball stud
Replace release fork and/or
ball stud
Oil on clutch disc damper
Replace clutch disc
Broken spring in slave cylinder
Replace slave cylinder
A "howling" or "whining" noise from the ring and pinion gear can be caused by an improper gear pattern, gear damage, or improper bearing
preload. It can occur at various speeds and driving conditions, or it can be continuous.
Before disassembling axle to diagnose and correct gear ke sure that tires, exhaust, and vehicle trim have been checked as possible causes.
Chuckle
This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It occurs while decelerating from 40
MPH and usually can be heard until vehicle comes to a complete stop. The frequency varies with the speed of the vehicle.
A chuckle that occurs on the driving phase is usually caused ive clearance due to differential gear wear, or by a damaged tooth on the coast
side of the pinion or ring gear. Even a very small tooth nick or a ridge on the edge of a gear tooth is enough the cause the noise.
This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding wheel. If either gear is damaged or scored
badly, the gear set must be replaced. If metal has broken loose, the carrier and housing must be cleaned to remove particles that could cause
damage.
Knock
This is very similar to a chuckle, though it may be louder, and occur on acceleration or deceleration. Knock can be caused by a gear tooth that
is damaged on the drive side of the ring and pinion gears. Ring gear bolts that are hitting the carrier casting can cause knock. Knock can also be
due to excessive end play in the axle shafts.
Clunk
Clunk is a metallic noise heard when an automatic transmission is engaged in Reverse or Drive, or when throttle is applied or released. It is
caused by backlash somewhere in the driveline, but not necessarily in the axle. To determine whether driveline clunk is caused by the axle,
check the total axle backlash as follows:
1. Raise vehicle on a frame or twinpost hoist so that drive wheels are free. Clamp a bar between axle companion flange and a part of the
frame or body so that flange cannot move.
2. On conventional drive axles, lock the left wheel to keep it from turning. On all models, turn the right wheel slowly until it is felt to be in
Drive condition. Hold a chalk marker on side of tire about 12" from center of wheel. Turn wheel in the opposite direction until it is
again felt to be in Drive condition.
3. Measure the length of the chalk mark, which is the total axle backlash. If backlash is one inch or less, drive axle is not the source of
clunk noise.
Bearing Whine
Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion bearings. Pinion bearings operate at
drive shaft speed. Roller wheel bearings may whine in a similar manner if they run completely dry of lubricant. Bearing noise will occur at all
driving speeds. This distinguishes it from gear whine, which usually comes and goes as speed changes.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel bearing. The lower pitch is because the
wheel bearing turns at only about 1/3 of drive shaft speed.
Chatter On Turns
This is a condition where the entire front or rear of vehicle vibrates when vehicle is moving. The vibration is plainly felt as well as heard. Extra
differential thrust washers installed during axle repair can cause a condition of partial lock-up that creates this chatter.
Axle Shaft Noise
Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally distinguish itself from gear noise by
occurring in all driving modes (Drive, cruise, coast and float), and will persist with transmission in Neutral while vehicle is moving at problem
speed.
If vehicle displays this noise condition, remove suspect parts, replace wheel seals and install a new set of bearings. Re-evaluate vehicle for
noise before removing any internal components.
Vibration
Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be constant or variable in level and can occur
during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can d into 3 main groups:
Vibrations of various unbalanced rotating parts of the vehicle.
Resonance vibrations of the body and frame structures caused by rotating of unbalanced parts.
Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline flexing modes.
DRIVE AXLE - RWD TROUBLE SHOOTING
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list
of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT,
DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing. For definitions of listed
noises or sounds, see
DRIVE AXLE - NOISE DIAGNOSIS
under POWERTRAIN.
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