Ford Festiva. Manual — part 64
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, clunk will not be eliminated by
overhauling drive axle.
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
driveshaft 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 driveshaft speed.
CHATTER ON TURNS
This is a condition where the whole front or rear vibrates when vehicle is moving. The vibration is easily felt and heard. Extra differential
thrust washers installed during axle repair can cause a condition of partial lock-up that creates the 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. Noise will persist with transmission in neutral while vehicle is moving at problem speed.
If vehicle displays this noise condition, remove suspect axle shafts and replace axle 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 con occur
during the total operating speed range of the vehicle.
The types of vibrations that can be felt in the vehicle can be divided 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 unbalance parts.
Tip-in moans of resonance vibrations from stressed engine or exhaust system mounts or driveline flexing modes.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
Copyright 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00002193
Back To Article
GENERAL INFORMATION
Gear Tooth Contact Patterns
* PLEASE READ THIS FIRST *
INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect for wear or damage. Mount dial indicator to housing and check backlash at several
points around ring gear. Backlash must be within specification at all points. If no defects are found, check gear tooth pattern contact.
GEAR TOOTH CONTACT PATTERN
1. Paint ring gear teeth with marking compound. Wrap cloth or rope around drive pinion flange to act as brake. Rotate gear until clear
contact pattern is obtained.
2. Contact pattern will indicate whether correct pinion bearing mounting shim has been installed and if drive gear backlash has been set
properly. Backlash between drive gear pinion must be maintained within specified limits until correct tooth pattern is obtained.
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
1. With no change in backlash, moving pinion further from ring gear moves drive pattern toward heel and top of tooth, and moves coast
pattern toward toe and top of tooth.
2. With no change in backlash, moving pinion closer to ring gear moves drive pattern toward toe and bottom of tooth, and moves coast
pattern toward heel and bottom of tooth.
3. With no change in pinion shim thickness, an increase in backlash moves ring gear further from pinion. Both drive and coast patterns
move toward heel and top of tooth.
4. With no change in pinion shim thickness, a decrease in backlash moves ring gear closer to pinion gear. Both drive and coast patterns
move toward toe and bottom of tooth.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
Drive pattern should be well centered on ring gear teeth. Coast pattern should be centered, but may be
slightly toward toe of ring gear teeth.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
Fig. 1: Drive Axle Gear Tooth Patterns
Copyright 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00091462
Back To Article
GENERAL INFORMATION
Clutch Trouble Shooting
* PLEASE READ THIS FIRST *
ALL MODELS
CLUTCH TROUBLE SHOOTING
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
NOTE:
This is GENERAL information. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For model-specific information see appropriate articles where
available.
Problem & Possible Cause
Action
Clutch Chatters/Grabs
Incorrect Pedal Adjustment
Adjust Free Play
Worn Input Shaft Spline
Replace Input Shaft
Binding Pressure Plate
Replace Pressure Plate
Binding Throw-Out Lever
Check Throw-Out Lever,
Check Throw-Out
Bearing, Check Bearing
Retainer
Uneven Pressure Plate Contact With Flywheel
Align/Replace Worn Parts
Transmission Misaligned
Align Transmission
Worn Pressure Plate
Replace Clutch Assembly
Oil-Saturated Disc
Replace Clutch Assembly,
Repair Oil Leak
Loose Engine Mounts
Replace Engine Mounts
Clutch Pedal Sticks Down
Clutch Cable Binding
Replace Clutch Cable
Weak Pressure Plate Springs
Replace Clutch Assembly
Binding Clutch Linkage
Lubricate Linkage
Broken Clutch Pedal Return Spring
Replace Return Spring
Clutch Will Not Release
Oil-Saturated Disc
Replace Clutch Assembly,
Repair Oil Leak
Defective Disc Face
Replace Clutch Assembly
Disc Sticking on Input Shaft Splines
Replace Disc/Input Shaft
Binding Pilot Bearing
Replace Pilot Bearing
Faulty Clutch Master Cylinder
Replace Master Cylinder
Faulty Clutch Slave Cylinder
Replace Slave Cylinder
Blown Clutch Hose
Replace Hose
Sticky Throw-Out Bearing Sleeve
Clean/Lube Sleeve
Clutch Cable Binding
Replace Clutch Cable
Broken/Loose Bellhousing
Check Bellhousing
Rattling/Squeaking
Broken Throw-Out Lever Return Spring
Replace Return Spring
Faulty Throw-Out Bearing
Replace Throw-Out
Bearing
Faulty Clutch Disc
Replace Clutch Disc
Faulty Pilot Bearing
Replace Pilot Bearing
Worn Throw-Out Bearing
Replace Throw-Out
Bearing
Dry Bearing Retainer Slide For Throw-Out Bearing Sleeve
Lubricate Slide
Slipping
Faulty Pressure Plate
Replace Clutch Assembly
Worn Clutch Disc
Replace Clutch Assembly
Incorrect Alignment
Realign Clutch Assembly
Faulty Clutch Slave Cylinder
Replace Slave Cylinder
No Pedal Pressure
Leaky Hydraulic System
Check Clutch Master
Cylinder, Check Clutch
Slave Cylinder
Check Clutch Hose
Broken Clutch Cable
Replace Clutch Cable
Faulty Throw-Out Lever
Replace Throw-Out Lever
Broken Clutch Linkage
Repair Clutch Linkage
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