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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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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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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