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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