M/T - Clutch Noise/Difficult to Shift

89ford01

Article No. 89-1-9

^ CLUTCH - "CLICKING" AND "CRACKLING" NOISE FROM UNDER THE INSTRUMENT PANEL - VEHICLES BUILT BEFORE 1/01/89

^ TRANSMISSION - MANUAL - DIFFICULT TO SHIFT; GEARS - SELF ADJUSTING CLUTCH CONTROLS
- VEHICLES BUILT BEFORE 1/01/89

^ NOISE - "CLICKING" AND "CRACKLING" FROM SELF ADJUSTING CLUTCH CONTROLS - VEHICLES BUILT BEFORE 1/01/89

MERKUR: 1985-89 XR4Ti 1988-89 SCORPIO

ISSUE: A "clicking" noise when the clutch pedal is depressed or a clutch pedal that slips when applied followed by a "crackling" noise when the clutch pedal is released may be caused by the self adjusting pawl slipping over the adjusting sector or a sticking clutch cable. These conditions do not allow the clutch assembly to completely disengage when the clutch pedal is depressed which results in a hard to shift transmission.


ACTION: Use the following service procedure to determine if a new self adjusting pawl and adjusting sector or a new clutch cable is required.

1. Listen for the "clicking" noise while fully depressing and slowly releasing the clutch pedal.

2. Make sure the clutch pedal travel is not obstructed and the clutch cable is installed correctly.

3. Make sure the clutch cable enters straight into the adjusting sector.

4. If the "clicking" noise still exists after performing Steps 1 through 3, install a new clutch cable.

FIGURE 5:

5. If a "crackling" noise is present after the new clutch cable has been installed, remove the self adjusting clutch mechanism from the vehicle, Figure 5. Refer to the appropriate Merkur Shop Manual, Section 16 for service details.

6. Install a new service self adjusting pawl and adjusting sector.

PART NUMBER PART NAME CLASS

E9RY-7L583-A Self Adjusting Pawl/Sector B

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic Warranty Coverage
OPERATION: 890109A - Replace Clutch Cable
TIME: 0.5 Hrs.
OPERATION: 890109B - Replace Clutch Cable and Self Adjusting Pawl/Sector
TIME: 0.8 Hrs.
DLR. CODING: Basic Part No. 7K553 -
Clutch Cable Replace
Condition Code: 41
DLR. CODING: Basic Part No. 7L583 -
Pawl/Sector Replace
Condition Code: 56
OASIS CODES: 5100, 5200, 5300, 5500, 5550