Ford Falcon. Manual — part 15
100-04-32
Noise, Vibration and Harshness
100-04-32
DIAGNOSIS AND TESTING (Continued)
Condition
Source
Action
Clutch grating/grinding noise—occurs
Clutch pressure plate fingers bent or
INSPECT the clutch pressure plate
release fingers. INSTALL a new
when clutch pedal is depressed
worn.
pressure plate as necessary. REFER
to Section 308-01 .
Contact surface of clutch release
INSTALL a new clutch release
bearing worn or damaged.
bearing. REFER to Section 308-01 .
Clutch chatter—a small amount of
Clutch engagement.
Acceptable operating condition.
noise when clutch pedal is released at
initial take-off
Clutch chatter/grabs—in some cases a
Damaged or worn powertrain/driveline
INSPECT the powertrain/drivetrain
shudder is felt—occurs with clutch
mounts. INSTALL new mounts as
mounts.
pedal depressed/released
necessary. REFER to Section 308-03 .
Binding or dragging plunger of the
CHECK the master and slave cylinder
clutch master cylinder or slave
operation. INSPECT the components
for damage or wear. INSTALL a new
cylinder.
master or slave cylinder as necessary.
REFER to Section 308-02 .
CHECK the input shaft seal and rear
Grease or oil on the clutch disc facing.
main oil seal. REPAIR as necessary.
INSTALL a new clutch disc. REFER to
Section 308-03 .
Clutch disc surface glazed or
INSPECT the clutch disc surface for a
glazed, hardened or damage
damaged.
condition. CARRY OUT a disc check.
INSTALL a new clutch disc as
necessary. REFER to Section 308-01 .
Damaged or worn clutch pressure
INSPECT the clutch pressure plate for
wear or damage. INSTALL a new
plate.
clutch pressure plate as necessary.
REFER to Section 308-01 .
INSPECT the flywheel for damage or
Flywheel surface damaged or glazed.
wear. CARRY OUT a flexplate/flywheel
runout check. INSTALL a new flywheel
as necessary. REFER to Section
303-01a for 2.0L Zetec engine or
Section 303-01b for 3.0L (4V) engine.
Clutch chatter noise—noise when
Pilot bearing worn, damaged or not
INSPECT the clutch pressure plate
clutch pedal is released at initial
release fingers for uneven wear, clutch
correctly aligned in bore.
take-off—clutch is hard to engage and
components burnt or a seized pilot
bearing. INSTALL a new pilot bearing
disengage
as necessary. REFER to Section
308-01 .
Loose flywheel bolts.
Clutch
vibration
Go to PinPoint Test K .
Damaged or loose clutch pressure
plate.
Excessive flywheel runout.
Transmission rattling/clattering
INSTALL a new gearshift lever.
Gearshift lever joint worn or damaged.
noise—noise at idle or on light
REFER to Section 308-06 .
acceleration from a stop—gear
selection difficult
TIGHTEN the bolts to specification.
Gearshift lever loose.
REFER to Section 308-06 .
Gearshift linkage rods worn or
CHECK the linkage bushings for wear.
INSTALL new linkage rods as
damaged.
necessary. REFER to Section 308-06 .
Transmission rattling/clattering
CHECK that the transmission is filled
Incorrect fluid level or fluid quality.
noise—occurs in neutral or in gear, at
to the correct level and with the
specified fluid. REFER to Section
idle
308-03 .
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100-04-33
Noise, Vibration and Harshness
100-04-33
DIAGNOSIS AND TESTING (Continued)
Condition
Source
Action
Transmission rattling/clattering
CHECK the reverse idler gear.
Worn or rough reverse idler gear.
REPAIR as necessary. REFER to
noise—noise at idle in neutral
Section 308-03 .
CHECK the ignition system. CARRY
Rough running engine, cylinder misfire.
OUT a cylinder power test. REFER to
Section 303-00 .
CHECK the gear backlash. ADJUST
Excessive backlash in gears
as necessary. REFER to Section
308-03 .
REPAIR as necessary. REFER to
Worn countershaft gears.
Section 308-03 .
Transmission whine—a mild whine at
Rotating gears/geartrain.
Acceptable noise.
extreme speeds or high rpm
Transmission whine—a high pitched
Transmission gears are worn (high
Result of normal gear wear. REPAIR
as necessary. REFER to Section
whine, also described as a squeal
mileage vehicle).
308-03 .
INSPECT the gear sets for an uneven
Mismatched gear sets.
wear pattern on the face of the gear
teeth. REPAIR as necessary. REFER
to Section 308-03 .
Damaged or worn transmission
INSPECT the transmission bearings.
INSTALL new bearings as necessary.
bearing.
REFER to Section 308-03 .
Transmission
INSPECT the transmission gears for
Gear is cracked, chipped or rough.
growling/humming—noise occurs in
damage or wear. INSTALL new gears
the forward gears—the noise is more
as necessary. REFER to Section
prominent when the gear is
308-03 .
loaded—the problem gear can be
located as the noise occurs in a
specific gear position
Transmission hissing—noise in neutral
INSPECT the transmission bearings.
Damaged or worn bearings.
or in forward gears—as bearings wear
INSTALL new bearings as necessary.
or break up, the noise changes to a
REFER to Section 308-03 .
thumping noise
Transmission
Bearings with damaged balls or rollers
INSPECT the transmission bearings.
knocking/thudding—noise at low
INSTALL new bearings as necessary.
or with pitted and spalled races.
speeds in forward gears
REFER to Section 308-03 .
Transmission rumble/growl—noise at
CHECK the driveline angle. REPAIR
Incorrect driveline angle.
higher speeds in forward gears, more
as necessary. REFER to Section
pronounced in a coast/deceleration
205-00 .
condition
CHECK the driveshaft for damage,
Driveshaft out of balance or damaged.
missing balance weights or
undercoating. Using the EVA, CHECK
the driveshaft balance. CARRY OUT a
driveline vibration test. REFER to
Section 205-01 . REPAIR as
necessary.
Transmission rumble/growl—noise at
Damaged or worn transmission
CHECK transmission fluid for
all speeds in forward gears, more
bearing or gears (high mileage
excessive metal particles. REPAIR as
pronounced in a heavy acceleration
vehicles).
necessary. REFER to Section 308-03 .
condition
Symptom Chart—Transmission (Automatic) Noise/Vibration
Condition
Source
Action
Rattle—occurs at idle or at light
Damaged engine or transmission
CHECK the powertrain/drivetrain
mounts for damage. INSTALL new
acceleration from a stop
mounts.
mounts as necessary. REFER to 303.
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100-04-34
Noise, Vibration and Harshness
100-04-34
DIAGNOSIS AND TESTING (Continued)
Condition
Source
Action
REPAIR or INSTALL a new heat shield
A loose front exhaust pipe heat shield.
as necessary.
Loose inspection plate or dust cover
CHECK for loose bolts. TIGHTEN to
specifications. REFER to Section
plate.
307-01 .
CHECK for loose nuts. TIGHTEN to
Loose flex plate to converter nuts.
specifications. REFER to Section
307-01 .
Whine—pitch increases with vehicle
Damaged or worn low one-way clutch.
INSPECT the transmission for wear or
speed—starts in first and second gear,
Damaged or worn intermediate
damage. REPAIR or INSTALL new
decreases or goes away at higher
one-way clutch.
components as necessary. REFER to
Friction elements.
gears
Section 307-01 .
Damaged or worn planetary or sun
gear.
Whine—the pitch changes with engine
A worn or damaged accessory drive
CARRY OUT the Engine Accessory
Test. REPAIR or INSTALL new
speed
component.
components as necessary. REFER to
Section 303-05 .
CHECK that the transmission is filled
Incorrect fluid level.
to the correct level. ADD fluid as
necessary. REFER to Section 307-01 .
INSPECT the filter. CLEAN or
Partially blocked filter.
INSTALL a new filter as necessary.
CARRY OUT the torque converter
Worn or damaged torque converter.
service and replacement check.
REFER to Section 307-01 .
INSPECT the front pump. INSTALL a
Worn or damaged front pump.
new front pump as necessary. REFER
to Section 307-01 .
Whine—pitch changes with vehicle
REPAIR or INSTALL new gears as
Speedometer gears.
speed
necessary.
Whine/moan type noise—pitch
Damaged engine or transmission
CHECK the powertrain/drivetrain
increases or changes with vehicle
mounts for damage. CARRY OUT
mount.
Powertrain/Drivetrain Mount
speed
Neutralizing in this section.
INSPECT the U-joints for wear or
U-joints worn or damaged.
damage. INSTALL new U-joints as
necessary. REFER to Section 205-01 .
Damaged or worn differential ring and
INSPECT the differential ring and
pinion for damage. CARRY OUT the
pinion.
Checking Tooth Contact Pattern and
Condition of the Ring and Pinion
component test in this section.
REPAIR or INSTALL a new differential
ring and pinion as necessary. REFER
to Section 205-02 .
CHECK the planetary gears for
Planetary gears nicked or chipped.
damage. INSTALL new components
as necessary. REFER to Section
307-01 .
Whistle—noise is high pitched,
INSPECT the main control. REPAIR or
Hydraulic pressure in the main control.
constant—changes in pitch with
INSTALL new components as
throttle position
necessary. REFER to Section 307-01 .
CARRY OUT the line pressure tests.
Incorrect band/clutch apply pressure.
REPAIR or INSTALL components as
necessary. REFER to Section 307-01 .
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100-04-35
Noise, Vibration and Harshness
100-04-35
DIAGNOSIS AND TESTING (Continued)
Condition
Source
Action
CARRY OUT the torque converter
Worn or damaged torque converter.
service and replacement check.
REFER to Section 307-01 .
Clunk—occurs when shifting from
INSPECT the powertrain mounts for
Damaged powertrain mounts.
damage. INSTALL new mounts as
PARK to a drive or reverse position
necessary. REFER to Section 307-01 .
CHECK for abnormal bearing play or
Damaged or worn pinion bearings.
roughness. INSTALL new bearings as
necessary. REFER to Section 205-02 .
INSPECT the CV joint. INSTALL a
Worn driveshaft CV joint.
new driveshaft as necessary. REFER
to Section 205-01 .
Worn friction elements or excessive
INSPECT the transmission for wear.
CHECK that all end play and
clutch pack end plate play.
clearances are within specification.
REPAIR or INSTALL new components
as necessary. REFER to Section
307-01 .
Bump—occurs when shifting from
Initial gear engagement.
Acceptable condition.
PARK to a drive or reverse
position—similar to Clunk but with no
sound
CHECK for correct driveline angles.
Buzz or hiss
Incorrect driveline angles.
REPAIR as necessary. REFER to
Section 205-00 .
Worn or damaged main control
INSTALL new components as
solenoids or valves.
necessary. REFER to Section 307-01 .
Vibration—a high frequency (20–80
Transmission cooler lines grounded
CHECK the transmission cooler lines.
Hz) that is felt through the seat or gear
out.
REPAIR as necessary.
shifter—changes with engine speed
Flexplate to torque converter nuts
CHECK the flexplate nuts. TIGHTEN
to specification. REFER to Section
loose.
307-01 .
CHECK the fluid filler tube. REPAIR as
Fluid filler tube grounded out.
necessary.
Shutter or chatter—occurs with light to
Electrical inputs/outputs.
CARRY OUT a Torque Converter
medium acceleration from low speeds
Vehicle wiring harness.
Clutch Operation Test. RUN on-board
Incorrect inputs/outputs from the
diagnostics or self–test. CLEAR the
or a stop
powertrain control module (PCM),
DTCs, ROAD TEST and RERUN
digital transmission range (TR) sensor,
on-board diagnostics or self–test.
brake pedal position (BPP) sensor,
throttle position (TP) sensor,
transmission speed sensor (TSS),
output speed shaft (OSS) sensor or
the torque converter clutch (TCC).
system for normal operation. Sometimes, it is
Pinpoint Tests
necessary to remove various vehicle components to
The pinpoint tests are a step-by-step diagnostic
gain access to the component requiring testing. For
process designed to determine the cause of a
additional information, refer to the appropriate section
condition. It may not always be necessary to follow a
for removal and installation procedures. Reinstall all
pinpoint test to its conclusion. Carry out only the steps components after verifying system operation is
necessary to correct the condition. Then, test the
normal.
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