Ford Festiva. Instruction - 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:

Article GUID: A00002193

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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:

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:

Fig. 1: Drive Axle Gear Tooth Patterns

Article GUID: A00091462

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GENERAL INFORMATION

Clutch Trouble Shooting

* PLEASE READ THIS FIRST *

ALL MODELS

CLUTCH TROUBLE SHOOTING

NOTE:

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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