2014 Mustang Workshop Manual

SECTION 308-03B: Manual Transaxle/Transmission — TR6060	2014 Mustang Workshop Manual
DIAGNOSIS AND TESTING	Procedure revision date: 02/05/2013

Manual Transmission

Inspection and Verification

NOTICE: If transmission noise is reported, first check the transmission fluid level. The vehicle should not be driven if the transmission fluid level is low. A low transmission fluid level will damage the transmission.

NOTE: If an observed or reported concern is found, correct the cause before proceeding.

Gear driven units produce a certain level of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Many conditions, such as road and weather can amplify normal vehicle noise.

The following overview is a guide to diagnose a transmission or clutch concern:

Verify and document the customer concern.
- During the customer interview, if a leak was noticed or if a leak is the concern, check the transmission fluid level. The vehicle should not be driven if the transmission fluid level is low.
Check fluid level and condition.
Evaluate the clutch hydraulic system.
Evaluate the clutch.
Inspect gearshift mechanism.
Evaluate the transmission.

Check Fluid Level and Condition

NOTICE: Excessive temperatures may break down the transmission lubricant. If there is reason to believe the transmission has been subjected to temperatures exceeding 135°C (275°F) for an extended period (greater than 20 minutes), change the lubricant immediately.

An incorrect transmission fluid level may affect the transmission operation and can result in transmission damage. For transmission draining and filling, refer to Transmission Draining and Filling .

A low transmission fluid level can result in poor transmission shifting, engagement or damage. It also indicates a leak in the transmission seals or gaskets.

Check the transmission fluid condition.
- Allow the transmission fluid to drip onto a white cloth and examine the stain. Check the transmission fluid for contamination or metal particles.

Evaluate Clutch Hydraulic System

Verify the clutch hydraulic fluid reservoir is filled to the correct level.
- If the clutch hydraulic fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks.

Evaluate the Clutch

Apply and release the clutch pedal slowly to check pedal binding. Make sure the clutch pedal can be fully applied and is not restricted by the floor mat.

With the engine idling and the park brake applied, move the gearshift lever into 4th gear. Increase engine speed to 2,000 rpm and slowly release the clutch pedal.
- If the engine stalls, the clutch is not slipping.
- If the engine does not stall, the clutch is slipping.

Inspect Gearshift Mechanism

Inspect the gearshift mechanism for:
- signs of damage.
- missing or loose fasteners.
- binding.

Repair as necessary.

Evaluate Transmission

NOTICE: The vehicle should not be driven if the transmission fluid level is low or damage may occur.

NOTE: Before attempting to repair any concerns, road test the vehicle to determine which system the concern is in.

Road test the vehicle. Use the following methods to diagnose the concern.
- Start the engine.
- Evaluate the noise in NEUTRAL while vehicle is parked.
  - Check whether the noise is present with the clutch fully disengaged (clutch pedal applied). Check to see if the pedal pulsates abnormally (clutch diaphragm finger runout).
  - Check whether the noise is present with the gearshift in the NEUTRAL position and the clutch fully engaged (clutch pedal released). Apply the park brake and move the gearshift towards the 1st gear position. Apply very slight pressure and note if the gear noise level is reduced (gear rollover noise).
  - With the clutch fully engaged (clutch pedal released) check whether the noise is present as the engine speed is raised. If the noise reduces, note the engine speed at which this occurs.
- Listen for any change in noise while applying and releasing the clutch pedal.
- Listen for any change in noise while changing the engine rpm.
- Drive the vehicle and shift through all the gears including REVERSE. Listen for any changes in noise.
- Drive the vehicle in the gear in which the noise is most noticeable. Apply the clutch pedal and leave the gear engaged. Listen for any change in noise.
- Drive the vehicle in the gear in which the noise is most noticeable. Apply the clutch pedal and shift the transmission into NEUTRAL. Release the clutch pedal and allow the vehicle to coast.

The following list of conditions are typical clutch concerns. Refer to Section 308-01 .
- Clutch slippage
- Clutch chatter or shudder
- Clutch pedal feels spongy or has excessive travel. Clutch will not disengage
- Clutch drag, also hard to shift
- Clutch pedal pulsation
- Clutch-related vibrations
- Excessive noise

The following list of conditions are typical clutch hydraulic system concerns. Refer to Section 308-02 .
- Clutch pedal feels spongy or has excessive travel. Clutch will not disengage
- Clutch drag, also hard to shift
- Clutch pedal pulsation
- Clutch system leakage

Compare the road test results with the following symptom charts. The following list of conditions are typical transmission concerns:
GO to Symptom Chart - Transmission Operation or GO to Symptom Chart - NVH .

Symptom Chart — Transmission Operation

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Symptom Chart — Transmission Operation
Condition	Possible Sources	Action
Transmission difficult to shift	Lubricant	ADD or DRAIN and FILL with specified lubricant. REFER to Transmission Draining and Filling .
	Internal shift mechanism	CHECK the internal shift mechanism for smooth operation. REPAIR or INSTALL a new mechanism as necessary.
	Sliding gears, synchronizers	CHECK for free movement of gears and synchronizers. REPAIR or INSTALL new components as necessary.
	Housings, shaft	CHECK for binding condition between the input shaft and the engine crankshaft pilot bearing or bushing. REPAIR or INSTALL new components as necessary. REFER to Section 308-01 .
	Loose pressure plate to flywheel bolts	CHECK for loose bolts at the pressure plate. INSTALL new components as necessary. REFER to Section 308-01 .
Transmission will not shift — gearshift lever moves	Gearshift lever damaged	INSTALL a new gearshift lever. REFER to Gearshift Lever .
	Damaged or worn selector arm. Loose shift rail bushings	CHECK the internal shift components. INSTALL new component as necessary.
	Damaged or worn shift plate	CHECK the internal shift components. INSTALL new component as necessary.
NOTE: While verifying the condition, determine whether the noise is gear rollover noise, release bearing rub or some other transmission-related noise. Gear rollover noise, inherent in manual transmissions, is caused by the constant mesh of gears turning at the engine idle speed while the clutch is engaged and the transmission is in NEUTRAL. Release bearing rub is sometimes mistaken for mainshaft bearing noise. Gear rollover noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Release bearing rub will disappear when the clutch is engaged. In the event that a bearing is damaged, the noise is more pronounced while engaged in gear under load or coast than in NEUTRAL. Noisy in forward gears	Lubricant	ADD or DRAIN and FILL with specified lubricant. REFER to Transmission Draining and Filling .
	Components grounding out on the transmission	CHECK for screws and bolts of body or other components grounding out. CORRECT as necessary.
	Components housing bolts	CHECK the torque on the transmission-to-flywheel housing bolts and the flywheel housing-to-engine block bolts. TIGHTEN the bolts to specification.
	Bearings or gears	INSPECT the bearings. INSPECT the gears and gear teeth for wear or damage. INSTALL new components as necessary.
Gears clash when shifting from one forward gear to another	Pilot bearing	CHECK for a binding condition between the input shaft and the engine crankshaft pilot bearing. INSTALL new components as necessary. REFER to Section 308-01 .
	Gear teeth and/or synchronizer	REPAIR or INSTALL new components as necessary.
	Damaged shift forks or worn shift fork inserts	INSPECT for wear or damage. INSTALL new components as necessary.
Transmission jumps out of gear	Transmission-to-engine mounting bolts	TIGHTEN the bolts to specification.
	Crankshaft pilot bearing	INSTALL a new pilot bearing. REFER to Section 308-01 .
	Internal damage	INSPECT the synchronizer sleeves for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surface. CHECK countershaft cluster gear for excessive end play. CHECK shift forks for worn or loose mounting on shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear or damage. REPAIR or INSTALL a new component as necessary.
	Gear teeth	If worn or damaged, INSTALL new gears.
Transmission will not shift into one gear — all others OK	Manual shift linkage	REPAIR or INSTALL new components as necessary.
	Backup switch ball	If REVERSE is the problem, CHECK reverse lamp switch for ball frozen in extended position.
	Internal components	INSPECT the shift rail and fork system, synchronizer system and the gear clutch teeth for restricted travel. REPAIR or INSTALL new components as necessary.
Transmission is locked in one gear and cannot be shifted out of that gear	Internal components	INSPECT the problem gears, shift rails, forks and the synchronizer for wear or damage. REPAIR as necessary.
	Fork on rail or shift rail	CHECK the shift rail interlock system. REPAIR as necessary.
	Offset lever	CHECK the shift rail interlock system. REPAIR as necessary.
Transmission leaks	Lubricant	CHECK the level and type.
	Other component leaking	IDENTIFY leaking fluid as engine, power steering or transmission fluid. REPAIR as necessary.
	False report	REMOVE all traces of lube on the exposed transmission surfaces. CHECK the vent for free breathing. OPERATE the transmission and INSPECT for new leakage. REPAIR as necessary.
	Internal components	INSPECT for leaks at the input shaft bearing retainer seal and the shift rail expansion plug on the. INSPECT for leaks at the top cover gasket. INSPECT the case for sand holes or cracks. REPAIR or INSTALL a new case as necessary.
	Fill and drain plugs	CHECK fill and drain plugs and bore threads. REPAIR as necessary. TIGHTEN plugs to specified torque value.
Bearing failure	Other part failure Raceways or rollers Lubricant Towing vehicle further than 80 km (50 mi) with driveshaft installed. Mainshaft tapered bearing and needle caged bearings are especially susceptible to damage.	REMOVE, DISASSEMBLE and CLEAN the transmission. Inspect for damaged parts and install new components as necessary. (Note: RESET the bearing preload if any new tapered bearings are installed.).
	Vibration break-up of retainer and brinelling of races Bearing(s) Shafts or bore Overloading of vehicle Incorrect preload	DETERMINE the cause of vibration and CORRECT. Otherwise, PROCEED as above.
	Input shaft oil dam	INSTALL new components as necessary and VERIFY the oil dam installation is correct. CHECK for correct installation of the snap ring on the mainshaft next to the oil dam.
	Oil baffle in the input bearing shim pack	INSTALL a new oil baffle, making sure it is not damaged during assembly.

Symptom Chart — NVH

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Symptom Chart — NVH
**NOTE:** NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
Condition	Possible Sources	Action
Transmission rattle noise — noise occurs at 1st and 2nd gear on light acceleration.	Gear engagement	Acceptable operating condition. Caused by the contact pattern of these gears.
Transmission rattling/clattering noise — occurs in NEUTRAL or in gear, at idle	Incorrect fluid level or fluid quality	COMPARE with other like vehicles. CHECK that the transmission is filled to the correct level and with the specified fluid. REFER to Transmission Draining and Filling .
Transmission rattling/clattering noise — noise at idle in NEUTRAL	Worn or rough reverse idler gear	CHECK the reverse idler gear. REPAIR as necessary.
	Excessive backlash in gears	CHECK the gear backlash. ADJUST as necessary.
	Worn countershaft gears	REPAIR as necessary.
Transmission whine — a mild whine at extreme speeds or high rpm	Rotating gears/geartrain	Acceptable noise.
Transmission whine — a high pitched whine, also described as a squeal	Transmission gears are worn (high mileage vehicle)	Result of normal gear wear. REPAIR as necessary.
	Mismatched gear sets	INSPECT the gear sets for an uneven wear pattern on the face of the gear teeth. REPAIR as necessary.
	Damaged or worn transmission bearing	INSPECT the transmission bearings. INSTALL new bearings as necessary.
Transmission growling/humming — noise occurs in the forward gears. The noise is more prominent when the gear is loaded. The problem gear can be located as the noise occurs in a specific gear position	Gear is cracked, chipped or rough	INSPECT the transmission gears for damage or wear. INSTALL new gears as necessary.
Transmission hissing — noise in NEUTRAL or in forward gears. As bearings wear or break up, the noise changes to a thumping noise	Damaged or worn bearings	INSPECT the transmission bearings. INSTALL new bearings as necessary.
Transmission knocking/thudding — noise at low speeds in forward gears	Bearings with damaged balls or rollers or with pitted and spalled races	INSPECT the transmission bearings. INSTALL new bearings as necessary.
Transmission rumble/growl — noise at higher speeds in forward gears, more pronounced in a coast/deceleration condition	Incorrect driveline angle	CHECK the driveline angle. REPAIR as necessary. REFER to Section 205-00 .
	Driveshaft out of balance or damaged	CHECK the driveshaft for damage, missing balance weights or undercoating. REFER to the driveshaft runout and balance test in Section 205-00 .
Transmission rumble/growl — noise at all speeds in forward gears, more pronounced in a heavy acceleration condition	Damaged or worn transmission bearing or gears (high mileage vehicles)	CHECK transmission fluid for excessive metal particles. REPAIR as necessary.