2012 Ford Focus

Powertrain Diagnostics & Repair / Transmissions / Clutch Manual and Hydraulic / M/T CLUTCH

Description and Operation

Clutch - Overview

Components of a clutch

Fig. 1: Identifying Clutch Components

Item Description

1 Flywheel

2 Clutch disc with friction lining

3 Cover assembly

A Sectional plane A

The clutch consists of:

Flywheel
Clutch disc
Cover assembly

When the clutch pedal is depressed, the clutch slave cylinder moves the release bearing which presses the center of the diaphragm spring
on to the compression ring towards the flywheel. The diaphragm spring fingers rest on diaphragm spring rings and lift the compression
ring from the clutch disc. The compression spring is relieved, allowing the flow of force to the transmission to be interrupted for gear-
changing.
If the clutch pedal is not depressed, force flows to the transmission due to the compressive force of the diaphragm spring on the
compression ring.
Self-adjusting clutches
The clutch size has also been increased with the introduction of more powerful engines. The self-adjusting clutch eliminates the increase
in operating force which occurs as wear increases.
The advantages of the self-adjusting clutch are as follows:

Constant operating force throughout the whole service life of the clutch.
Increased service life of the clutch friction disc.
Shorter release bearing travel.

Self-adjusting clutches cannot be reset after the clutch friction disk has been renewed and must also be renewed.

Clutch - System Operation and Component Description

System Operation
How the clutch works
Cross-sectional view of a single-disc dry clutch

Fig. 2: Cross-Sectional View Of Single-Disc Dry Clutch

Item Description

A Clutch disengaged

B Clutch engaged

1 Flywheel

2 Clutch disc with friction lining

3 Pressing ring

4 Diaphragm spring

5 Transmission input shaft

6 Clutch cover

7 Crankshaft Dimensions

The clutch transmits the torque from the engine to the transaxle; when the clutch pedal is depressed the power transmission from the
engine to the transaxle is interrupted.
When the clutch pedal is not depressed the clutch is engaged. Pressing down the pedal disengages the clutch.
A dry clutch usually only has one clutch disc, the coatings of which are specially designed for dry friction with a higher coefficient of
friction. The torque which can be transmitted also depends on the size and number of friction surfaces and the pressing force.
The flywheel and pressing ring are connected to the crankshaft in a rotationally fixed way and transmit the torque via the friction linings of
the clutch disc to the input shaft of the transaxle. The clutch disc is clamped between the flywheel and the pressing ring. The force from
the diaphragm spring provides the necessary contact pressure.
The clutch cover, pressing ring and diaphragm spring are also referred to jointly as the cover assembly .
The wear on the clutch disc is greatest at the pressure point during engagement of the clutch. If the pressing ring is moved away from the
flywheel then there is no longer any friction to the clutch disc, and the connection is disengaged.
The most frequent damage observed on the clutch is too low friction (sliding) between the clutch disc and the pressing ring or flywheel.
This can be caused by oil leaks, friction lining wear or a weakening diaphragm spring.

Diagnosis and Testing

Clutch

Symptom Chart(s)
Symptom Chart: Clutch
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

Condition Possible Sources Actions

Clutch slippage Clutch pedal reserve Go to Pinpoint Test A

Worn or damaged pressure plate

Clutch disc facing

Hardened or oiled clutch disc

facing surface

Flywheel

Clutch chatter, rattle Loose or damaged engine or GO to Pinpoint Test B

or shudder transaxle mounts

Oil on clutch disc facing

Worn pressure plate

Clutch disc facing

Loose or damaged flywheel

Worn clutch disc

Clutch drag Insufficient clutch hydraulic fluid GO to Pinpoint Test C

Air in hydraulic system

Clutch pedal reserve

Diaphragm springs

Clutch disc

Clutch disc splines

Oil on clutch disc facing

Clutch pedal Clutch and brake pedal pivot GO to Pinpoint Test B

pulsation shaft not correctly lubricated

Flywheel

Worn pressure plate springs

Clutch related Engine component grounding GO to Pinpoint Test B

vibrations against frame

Accessory drive belt

 Condition Possible Sources Actions

Flywheel bolts loose

Flywheel

Imbalanced clutch pressure plate

Hard shifting Insufficient clutch hydraulic fluid GO to Pinpoint Test C

Clutch pedal reserve

Transaxle concern

Clutch system Clutch master cylinder INSPECT the clutch master cylinder, the clutch slave cylinder and
leakage Clutch slave cylinder all hydraulic system tubes for leakage. REPAIR as necessary.

Clutch hydraulic tubes

Pinpoint Test(s)
PINPOINT TEST A

A1 TEST CLUTCH SLIPPAGE

Apply the parking brake.

Start engine and engage 4th gear.
Run the engine at approximately 2, 000 rpm.
Slowly release clutch pedal.

Does the engine stall when the clutch pedal is fully released?

Yes: Clutch is OK.

No: GO to A2

A2 MEASURE THE CLUTCH RESERVE

NOTE: If equipped, remove the floor mat to allow the clutch pedal to travel to the downstop.

Install a cable tie to the clutch pedal, than attach a tape measure to the cable tie.
Pull the tape measure up to the steering wheel. Position it through the steering wheel opening. Put a piece of masking tape on the
steering wheel and index mark the masking tape.
Press the clutch pedal fully and start the vehicle.
Shift the transaxle into REVERSE gear, then move the gearshift lever forward to the position in between REVERSE gear and
NEUTRAL. Slowly release the clutch pedal (if the vehicle creeps rearward, move the gearshift lever forward a little more). The
transaxle will work as if in NEUTRAL, but the reverse gear synchronizer will be bypassed.
With the clutch pedal released, gently pull the gearshift lever toward the REVERSE gear position. Gear clash can now be heard.
Slowly press the clutch pedal. Using the mark on the tape as a reference, note the measurement when the gear clash stops or the
gearshift lever slides into REVERSE gear. Press the clutch pedal to the downstop. The difference between the measurement taken
when the gear clash stopped and the measurement taken at the downstop is the clutch reserve.

Item Pedal Position

1 Gear clash begins

2 Gear clash ends

3 Clutch pedal downstop

Is the clutch reserve between -?

Yes: Clutch pedal reserve is OK. VERIFY customer concern.

No: INSTALL a new pressure plate and clutch disc.

 REFER to: Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75 .
PINPOINT TEST B

B1 CHECK THE ENGINE OR TRANSAXLE MOUNTS

Inspect all the engine and transaxle mounts for looseness or damage.

Are any of the engine or transaxle mounts loose or damaged?

Yes: TIGHTEN or INSTALL new engine or transaxle mounts. TEST the system for normal operation.

No: GO to B2

B2 INSPECT THE PRESSURE PLATE BOLTS

Inspect the pressure plate-to-flywheel bolts.

Are any of the pressure plate-to-flywheel bolts loose?

Yes: TIGHTEN or INSTALL new bolts.

REFER to: Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75 .
No: GO to B3

B3 INSPECT THE PRESSURE PLATE

Remove the clutch pressure plate.

Inspect the clutch pressure plate for wear or damage.

Are any signs of damage present on the clutch pressure plate?

Yes: INSTALL a new clutch pressure plate.

REFER to: Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75 .
TEST the system for normal operation.
No: GO to B4

B4 CHECK THE CLUTCH DISC

NOTE: If the internal damper of the clutch disc is damaged or contaminated with grease or oil, it will sound similar
to a "transaxle rattle".

Check the clutch disc for wear or damage.

Is the clutch disc OK?

Yes: GO to B5

No: INSTALL a new clutch disc.

REFER to: Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75 .
TEST the system for normal operation.

B5 INSPECT THE FLYWHEEL

Inspect the flywheel for wear or damage.

Is the flywheel OK?

Yes: GO to B6

No: REPAIR or INSTALL a new flywheel as necessary.

REFER to: Flywheel ( FLYWHEEL .

TEST the system for normal operation.

B6 INSPECT THE INPUT SHAFT

Inspect the input shaft for signs of wear, damage or corrosion.

Are any signs of wear damage, or corrosion present on the input shaft?

Yes: If wear or damage is found, INSTALL a new input shaft.

REFER to: Manual Transmission ( MANUAL TRANSMISSION (Vehicles With: 5-Speed Manual Transmission - MTX75) .
or REFER to: Manual Transmission ( MANUAL TRANSMISSION (Vehicles With: 6-Speed Manual Transmission - MMT6) .
 If corrosion is found on the splines of the input shaft, apply a small amount of grease to the splines of the input shaft.
No: VERIFY the customer concern. Refer to Symptom Chart: Transmission

REFER to: Manual Transmission ( MANUAL TRANSMISSION (Vehicles With: 5-Speed Manual Transmission - MTX75) .
or REFER to: Manual Transmission ( MANUAL TRANSMISSION (Vehicles With: 6-Speed Manual Transmission - MMT6) .
PINPOINT TEST C

C1 CHECK CLUTCH FLUID LEVEL

Check clutch fluid level.

Is the clutch fluid level between the MAX and MIN marks on the brake fluid reservoir?

Yes: GO to C2

No: FILL reservoir to specification, CHECK the brake and clutch systems for leaks. TEST clutch system for normal operation.

C2 TEST CLUTCH PEDAL FREE TRAVEL

Manually operate the clutch pedal to the point of resistance and release.
Measure pedal travel.

Is the measured dimension within?

Yes: GO to C3

No: GO to C2

C3 CHECK THE BELLEVILLE SPRING WASHER OF THE CLUTCH PRESSURE PLATE

Remove transmission.
REFER to: Manual Transmission ( MANUAL TRANSMISSION (Vehicles With: 5-Speed Manual Transmission - MTX75) .
or REFER to: Manual Transmission ( MANUAL TRANSMISSION (Vehicles With: 6-Speed Manual Transmission - MMT6) .

Does the clutch pressure plate or the Belleville spring washer of the clutch pressure plate show signs of wear or damage?

Yes: INSTALL a new clutch pressure plate.

REFER to: Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75 .
TEST the system for normal operation.
No: VERIFY the customer concern.

COMPONENT TEST (S)

Clutch

1. Slowly press and release the clutch pedal to see if the pedal is binding. Make sure the clutch pedal can be fully pressed and is not
restricted by the floor mat. Verify the pedal return spring is present and is functioning correctly.
2. Measure the clutch reserve. GO to Pinpoint Test A
3. With the engine idling, the parking brake on and the clutch pedal up, gently move the gearshift lever into a forward or reverse gear,
until gear clash can be heard. Slowly press the clutch pedal.
4. If the gears cease to clash (full disengage at - from the floor), hold the pedal at the point of disengagement and increase engine to 4,
000 rpm. If the clutch remains disengaged, it is functioning correctly.
5. Any concerns indicate a worn or damaged clutch. Repair as necessary.
6. With the engine idling, move the gearshift lever into 4th gear. Increase the engine to 2, 000 rpm and slowly release the clutch pedal.
7. If the engine stalls, the clutch is OK.
8. If the engine does not stall, the clutch is slipping. Repair as necessary.
9. Compare the road test results with the symptom chart. The chart is a list of conditions that are typical faults.
REFER to: Clutch .

Removal and Installation

Clutch Disc and Pressure Plate - Vehicles With: 5-Speed Manual Transmission - MTX75

Removal

1. Refer to: Transmission ( REMOVAL (Vehicles With: 5-Speed Manual Transmission - MTX75) .
 2. Loosen each bolt 2 turns at a time until all bolts are removed.

Fig. 3: Identifying Loosening Sequence Of Clutch Disc And Pressure Plate Bolts (5 Speed Manual Transmission)

Installation

1. Special Tool(s): Universal clutch alignment tool.

Fig. 4: Installing Universal Clutch Alignment Tool

2. Tighten each bolt 2 turns at a time.

Torque : 29 Nm

Fig. 5: Identifying Tightening Sequence Of Clutch Disc And Pressure Plate Bolts (5 Speed Manual Transmission)

3. Refer to: Transmission ( INSTALLATION (Vehicles With: 5-Speed Manual Transmission - MTX75) .

Clutch Disc and Pressure Plate - Vehicles With: 6-Speed Manual Transmission - MMT6

Removal

1. Refer to: Transmission - 2.0L EcoBoost ( REMOVAL (Vehicles With: 6-Speed Manual Transmission - MMT6) ).

2. Fig. 6: Identifying Loosening Sequence Of Clutch Disc And Pressure Plate Bolts (6 Speed Manual Transmission)

Installation
1. Fig. 7: Installing Clutch Puller

2. Turn clockwise until the pressure plate mounting surfaces are in contact with the flywheel.
Torque : 22 Nm

Fig. 8: Turning Clutch Puller To Clockwise Direction

3. 1. Torque : 22 Nm
2. Torque : 29 Nm

Fig. 9: Locating Pressure Plate Mounting Bolts

4. Refer to: Transmission - 2.0L EcoBoost ( INSTALLATION (Vehicles With: 6-Speed Manual Transmission - MMT6) .

Created/Modified Date: 2/12/2013 4:32:24 PM