Ford Falcon. Manual — part 257
308-02-1 Clutch
Controls 308-02-1
SECTION : 308-02 Clutch Controls
VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS
PAGE
SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-02-2
DESCRIPTION AND OPERATION
Clutch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-02-3
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . ...308-02-3
DIAGNOSIS AND TESTING
Clutch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-02-4
Inspection and Verification - Clutch . . . . . . . . . . . . . . . . . . . . . .308-02-4
Function
Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...308-02-4
Symptom
Chart
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-02-4
Pinpoint
Tests
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-02-6
GENERAL PROCEDURES
Clutch Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-02-8
REMOVAL AND INSTALLATION
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-02-9
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-02-9
Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-02-10
Clutch Hydraulic Fluid Tubes . . . . . . . . . . . . . . . . . . . . . . . ..308-02-10
Clutch Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-02-11
308-02-2 Clutch
Controls 308-02-2
SPECIFICATIONS
General Specifications
Description
Specification
Clutch System
Clutch control
Hydraulic
System adjustment
Automatic
Clutch pedal type
Suspended
Fluid
Brake Fluid (Ford)
Mobil ESZ - M6C55A
Torque Specifications
Description
Nm
Clutch Pivot Bolt
20
Master Cylinder retaining bolts
14
Adjuster Motor Retaining Bolts
5
± 0.5
(adjustable pedal)
Pedal Box Housing
22.5
± 3.4
Brake Booster Retaining Nuts
22.5
± 3.4
Clutch Pivot Bolt (M8)
16
± 2
Clutch Assembly Bolt (M6)
6
± 0.5
Reservoir Bracket Bolts
2 - 4
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308-02-3 Clutch
Controls 308-02-3
DESCRIPTION AND OPERATION
Clutch Controls
Component Location
Acronyms and Abbreviations
Item
Description
1
Clutch pedal deactivation switch
APM
Accelerator Pedal Module
2
Clutch reservoir
PCM
Power Train Module
3
Brake and clutch pedal support bracket
BEM
Body Electronic Module
4
Clutch master cylinder
Step Over
Height Difference Between Brake and
5
Clutch slave cylinder/clutch release hub
Accelerator Pedal
and bearing
MSC
Memory Seat Controller
The clutch control system actuates the clutch system.
PPS
Pedal Position Sensor
When the clutch pedal is depressed it pushes the
clutch master cylinder plunger which transmits
hydraulic pressure to the clutch slave cylinder. The
clutch slave cylinder engages and compresses the
clutch pressure plate diaphragm spring, releasing the
pressure on the clutch disc which in turn disengages
the transmission from the engine.
The hydraulic clutch system adjusts automatically
to compensate for clutch disc wear.
The clutch pedal starter interlock switch is
attached to the clutch pedal. Depressing the
clutch pedal manually closes the switch and
allows engine cranking.
The clutch pedal deactivation switch deactivates
the speed control system when the pedal is
depressed.
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308-02-4 Clutch
Controls 308-02-4
DIAGNOSIS AND TESTING
Function Test
Clutch Controls
Condition
Possible
Function
Pin Point
Inspection and Verification - Clutch
Source
Test
Test
The transmission and the clutch transfer the engine
PEDAL
Pedal Slow or Manual
B
torque to the wheels. When diagnosing the
FEEL
does not
Application
transmission. Both the transmission and the clutch
return
Test of the
should be considered when diagnosing concerns.
Clutch
Verify the customer concern by operating the
Pedal to
system.
confirm
Visually inspect for obvious signs of mechanical
Binding /
Manual
C
damage.
Raspy pedal
Test
If an obvious cause for an observed or reported
Worn Pedal
Visual
concern is found, correct the cause ( if possible)
Pad
Inspection
before proceeding to the next step.
Clutch Pedal
Refer to
If the concern is not evident, verify the symptom
"Sinks" sinks
Clutch
and refer to the Symptom Chart
to the Floor
Diagnosis
in Section
Check these items before entering Diagnostics.
206-06
Topic
Specification
CRUISE
Not
Visual
A
Brake Fluid
Ensure that the Reservoir is Filled
CONTROL Functioning
Inspection
Reservoir
to the Max Point. Use Ford
CLUTCH
Adjustment
Visual
Approved Brake Fluid Mobil ESZ -
SWITCH
Inspection
M6C55A .
Switch
Visual
A
CAUTION: Do not allow
Disconnected Inspection
brake fluid to contact vehicle
HARD TO
Master
Visual
paint work.
ENGAGE
Cylinder
Inspection
Vehicle Test
Ensure That Your Local State
GEARS
Leakage
Drive to
Speed Limits are Not Exceeded
Slave
Visual
Refer to
Confirm Fault
Cylinder
Inspection
Clutch
Battery Voltage Must be Greater Than 12 Volts
Leakage
Diagnosis
in section
Obstructions
Check for Any Obstructions at the
308-01
Brake Pedal Area, Such as Floor
Mats and Wiring Harnesses
HARD TO
Clutch Plate
Refer to
ENGAGE
Worn
Clutch
Visual Inspection Chart
GEARS
Diagnosis
Electrical
(ctd)
in section
Oil leaks
308-01
Visibly damaged or worm parts
Pressure
Refer to
Loose or missing nuts or bolts
plate Issue
Clutch
Diagnosis
in section
308-01
Air in System
Refer to
Clutch
Diagnosis
in section
308-01
Symptom Chart
Symptom Chart - (MSC) Memory Seat Controller
Condition
Source
Action
Excessive effort needed to depress
Clutch pedal binds at pivot
INSTALL a new clutch pedal
clutch pedal or has a rough or raspy or
sticky feel
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