308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5	2014 Fiesta
Diagnosis and Testing	Procedure revision date: 08/22/2013

Manual Transmission

Inspection and Verification

NOTICE: If transmission noise is reported, check the fluid level first. Do not drive the vehicle if the fluid level is low or damage can occur.

Verify the customer concern.

Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical
Oil leaks. Visibly damaged or worn components. Loose or missing nuts or bolts.

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

If the cause is not evident, verify the symptom and REFER to the Symptom Chart.

The following checks should be carried out before repairing or installing a new transmission.

The inspection and verification of manual transmission concerns can be considered in three main areas.

Gear Shifting Concerns

Clutch does not operate correctly.
External gearshift mechanism.
REFER to: External Controls (308-06 Manual Transmission External Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Diagnosis and Testing).

Transmission noise concerns

Check the engine and transmission mountings for sufficient clearance to the transmission and the body.
Any other noise excluding shift noises.
Road test the vehicle. Carry out the checks in the following table and record the results.

Fluid Leakage Concerns

Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the hydraulically operated clutch) or engine oil.
Check the transmission fluid level. If necessary, drain off any excess fluid.
Locate the oil leak with the aid of a fluorescent test fluid and an ultraviolet inspection lamp.
Clean the transmission and the adjacent areas carefully before road testing.

Symptom Chart – Transmission Operation


Symptom	Possible Sources	Action
Gears clash when shifting from one forward gear to another	Gear teeth/synchronizer damaged	INSPECT and REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Transmission jumps out of gear	Bolts retaining transmission to engine loose Preload incorrect Internal components damaged Gear teeth worn/damaged	TIGHTEN the bolts to specification. REFER to: Transmission - 1.0L EcoBoost (90kW/120PS) (308-03A) . CHECK preload. INSPECT the synchronizer for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surface. CHECK the countershaft cluster gear for excessive end play. INSPECT the shift forks for wear. CHECK for loose shift forks on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear and damage. REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly). INSPECT and REPAIR as necessary. REFER to Section 308-03.
Transmission will not shift into one gear — all others OK	Internal components	For the gear in question, INSPECT the shift rail and fork, the synchronizer, and the gear clutch teeth for restricted travel. REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Transmission is locked in one gear and will not shift out of that gear	Internal components	INSPECT the gears, the shift rails, the forks and the synchronizer for wear or damage. REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Fluid leaks	Transmission fluid Other components leaking Halfshaft seals Input shaft seal Fill and drain plugs	CHECK the transmission fluid level and type. REMOVE all traces of fluid on exposed transmission surfaces. CHECK the vent for free breathing. OPERATE the transmission and INSPECT for new leakage. IDENTIFY the leaking fluid as engine, power steering or transmission fluid. REPAIR as necessary. INSPECT and INSTALL new seals as necessary. REFER to: Halfshaft Seal LH (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation). REFER to: Halfshaft Seal RH (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation). INSPECT, and REPAIR as necessary. REFER to: Input Shaft Seal (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Removal and Installation). INSPECT the plug, O-ring, and the threads in the case. REPAIR as necessary. TIGHTEN the plug to specification. REFER to: Transmission Fluid Level Check (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, General Procedures).
Significant effort required when downshifting	Gear synchronization is inadequate. Gear teeth/synchronizer damaged	INSPECT the transmission. INSTALL a new synchronizer assembly with synchronizer rings. INSTALL two new gears belonging to the synchronizer assembly. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Stiff gearshift	Transmission fluid Damaged synchronizer rings or inner selector mechanism	CHECK that the transmission is filled with the specified transmission fluid and, if necessary, FILL and ADD transmission fluid as necessary. CHECK the internal components for wear or damage, REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
One of the gears cannot be selected	Fault between the gearshift lever and gearshift lever housing	INSPECT the gearshift lever. REFER to: External Controls (308-06 Manual Transmission External Controls - Vehicles With: 5-Speed Manual Transmission - B5/IB5/6-Speed Manual Transmission - B6, Diagnosis and Testing).
Reverse gear cannot be selected	Gearshift lever Internal components	CHECK the gearshift lever for damage. REPAIR as necessary, remove the gearshift lever to see whether reverse gear can be selected. CHECK the reverse idler gear and the appropriate selector fork, shift rail and synchronizer unit. REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Grinding or clashing noises when shifting into 3rd gear	Deflected lubrication condition causing early 3rd gear wear	INSTALL a new 3rd gear, 3rd/4th gear shift fork, outer synchronizer ring, inner synchronizer ring, 3rd gear synchronizer cone, 3rd/4th gear synchronizer assembly. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).

Symptom Chart - Transmission 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: Noise, Vibration and Harshness (NVH) 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 system for the symptom, Refer to: Noise, Vibration and Harshness (NVH) Section 100-04.


Symptom	Possible Sources	Action
Noisy in forward gears — noise described as rattle or a knock	Transmission fluid level low/incorrect type Components grounding out on transmission Bearings/gears worn/damaged Bolts retaining transmission to engine loose	ADD or REFILL with the specified transmission fluid. REFER to: Transmission Fluid Level Check (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, General Procedures). CHECK for screws and bolts of chassis components grounding out. REPAIR as necessary. INSPECT the bearings, the gears, and the gear teeth for wear and damage. REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly). VERIFY the bolts are tightened to specification. REFER to: Transmission - 1.0L EcoBoost (90kW/120PS) (308-03A) .
Noise in NEUTRAL occurs after hot soak or under load	Neutral rollover noise transmission	A slight rollover gear noise is an acceptable condition. INSTALL a new clutch disc. REFER to: Clutch Disc and Pressure Plate - 1.0L EcoBoost (90kW/120PS) (308-01A) . INSPECT and REPAIR as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Slight buzzing, rattling or metallic scraping noise from the transmission at 2,500 to 3,500 rpm when coasting or driving without load (particularly in 2nd and 3rd gear)	Rotational vibration from the engine not sufficiently damped by the clutch	These noises do not affect the operation and durability of the transmission.
Brief scratching noise during gear shifting	Inadequate gear synchronization	INSPECT the transmission for wear or damage. REPAIR as necessary. INSTALL a complete synchronizer assembly with synchronizer rings. INSTALL two new gears belonging to the synchronizer assembly. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).
Gear growl — to occur, lug the engine in 1st or 2nd gears, press the throttle to floor and the noise will be heard	Reduced preload on the input shaft	Acceptable noise under these conditions.
Gear whistle — occurs in 2nd, 3rd and 4th gear by pressing the throttle to the floor and letting the vehicle accelerate, hard acceleration to WOT , a very light whistle noise can be heard	Driven gears on the output shaft	Acceptable noise under these conditions.
Clicking noises in reverse gear	Reverse gear	INSPECT the gears for wear or damage. INSTALL new gears as necessary. REFER to: Transmission (308-03A Manual Transmission - Vehicles With: 5-Speed Manual Transmission - B5/IB5, Disassembly).