Ford 2002 Bantam Workshop Manual page 892

308-00-4
DIAGNOSIS AND TESTING
Symptom Charts
Poor Gear Shifting
Condition
• Significant effort required when
downshifting or synchronizer
crashing
• Gear jumps out of engagement
while driving.
• Gearshift problems in different
gears (stiff or partially seized).
• Gearshift problems in the neu-
tral slot (sticking, scraping, lock-
ing).
Transaxle Noises
Condition
• Slight buzzing, rattling or metal-
lic scraping noise from the
transaxle at 2500 to 3500
rev/min when coasting or driving
without load (particularly in 2nd
and 3rd gear).
E6760 EN
Manual Transaxle and Clutch — General Information
Possible Sources
• Gear synchronization is inade-
quate.
• Transaxle assembly error
(missing snap rings or
synchronizer components).
• Manufacturing error
(INCORRECT gear wheel
toothing or synchronizer ring).
• Selector fork.
• Transaxle assembly error: miss-
ing snap rings or synchronizer
components, foreign materials in
the transaxle. Bolts of selector
components loose.
• Reversing lamp actuating pin
loose.
• Reversing lamp actuating pin
wrongly installed (chamfer at the
selector shaft rotated by 180
degrees).
Possible Sources
• Rotational vibration from the en-
gine not sufficiently damped by
the clutch.
Action
• INSTALL a complete set
(synchronizer hub with
synchronizer rings) and
INSTALL two new gear wheels
belonging to the synchronizer
unit.
• Because of various changes
and the difficulty in estimating
the level of wear, a complete
new installation (as described
above) is recommended.
• INSTALL a new gear
set/synchronizer unit and selec-
tor fork concerned as neces-
sary. CHECK the transaxle for
any resulting damage, particu-
larly on the reverse gear syn-
chronizer.
• REPAIR the transaxle accord-
ingly. CHECK the transaxle for
any resulting damage.
NOTE: There is a risk of breaking
the actuating pin when screwing
it in.
• TIGHTEN the actuating pin to 6
Nm.
• REPAIR the gearshift cover or
INSTALL a new gearshift cover
as necessary.
• Use new bolts and install them
using locking compound.
Action
• These noises do not affect the
operation and durability of the
transaxle.
07/2001 2002 Bantam
308-00-4