SECTION 308-00: Manual Transmission/Transaxle and Clutch - General Information
1998 Contour/Mystique Workshop Manual
DESCRIPTION AND OPERATION
Manual Transaxle and Clutch
Manual Transaxle and Clutch - General Information
This section covers general procedures for diagnosis and testing the clutch system. For additional information, refer to Section 308-01 . For specified clutch system service procedures. For additional information, refer to Section 308-02 . For a complete description of the manual transaxle. For additional information, refer to Section 308-03 .
The clutch system includes:
The clutch master cylinder transmits fluid pressure to the slave cylinder, which in turn moves the clutch release fork and the clutch release hub and bearing.
The clutch master cylinder uses brake fluid and shares a common reservoir with the brake master cylinder
The clutch is a single plate, dry-friction disc with a diaphragm-style spring clutch pressure plate. The clutch disc has a hub which is splined to the input shaft. The clutch disc has friction material where it contacts the flywheel and the clutch pressure plate. Torsion springs on the clutch disc help absorb the engine torque pulses. The clutch pressure plate applies pressure to the clutch disc, holding it tightly against the surface of the flywheel.
In the engaged position, the diaphragm spring holds the clutch pressure plate against the clutch disc, so that engine torque is transmitted to the input shaft. When the clutch pedal is depressed, the clutch release hub and bearing pushes the diaphragm spring center toward the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted to the clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transaxle and enabling the gears to be changed.
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Inspection and Verification - MTX-75
The following checks should be carried out before repairing or replacing the transaxle:
Poor gear shifting
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Symptom Chart - General Concerns Condition Possible Sources Action Clicking noises in reverse gear
Gear wheels.
INSTALL new gear wheels.
Gear wheels banging when shifting.
Damaged clutch.
Selector forks or synchronizer rings.
For additional information, refer to Section 308-01 .
CHECK the components for damage.
Noises in the forward gears
Transaxle fluid level too low.
The engine/transaxle assembly is in contact with the chassis/body.
Engine/transaxle flange bolts.
Input and output shaft bearings. Gear wheels (usually on high-mileage vehicles).
Top up the transaxle fluid.
Look for points of contact or damaged engine/transaxle isolator, roll resistor.
TIGHTEN the transaxle flange bolts. For additional information, refer to Section 308-03 .
Remove the transaxle. CHECK the bearings and gear wheels and INSTALL new parts as necessary.
Stiff gearshift
Transaxle fluid.
Damaged synchronizer rings or inner selector mechanism.
CHECK that the transaxle is filled with the specified transaxle fluid and, if necessary, fill up with transaxle fluid of the type listed under "Specifications".
CHECK the internal components for damage, INSTALL new parts as necessary.
Gears jump out of engagement
Malfunction between the gearshift lever and the gearshift lever housing.
Engine/transaxle isolator, roll resistor.
Internal components.
Adjust the gearshift mechanism or repair the fault.
REPAIR or INSTALL new components as necessary.
CHECK the selector shafts, selector forks and synchronizer units and INSTALL new parts as necessary.
One of the gears cannot be selected
Fault between the gearshift lever and gearshift lever housing.
Adjust the gearshift mechanism or repair the defect.
3rd gear jumps out of engagement
Internal selector mechanism loose, causing the selector finger guide to move on the inner selector shaft.
TIGHTEN the pin to 25 Nm.
Reverse gear cannot be selected
Outer gearshift mechanism.
Internal components.
CHECK the outer gearshift mechanism for damage. As necessary, remove it to see whether reverse gear can then be selected.
Remove the transaxle assembly and CHECK the reverse gear idler and the appropriate selector fork, selector shaft and synchronizer unit. INSTALL new parts as necessary.
Stiff gearshift
Gearshift lever housing broken or damaged.
Joint housing.
Gearshift lever joint.
Gearshift lever not securely attached to mounting.
INSTALL a new gearshift lever housing.
INSTALL a new gearshift lever as necessary.
INSTALL a new gearshift lever as necessary.
TIGHTEN or INSTALL new self-tapping screws.
Clattering, rattling or booming noises
Gearshift lever joint.
Gearshift lever knob loose.
INSTALL a new gearshift lever.
TIGHTEN the gearshift lever knob or, INSTALL a new as necessary.
Gearshift lever not functioning - no gear can be selected
Gearshift lever housing detached at the floor assembly.
Secure the gearshift lever housing.
Gearshift lever feels loose
Gearshift lever joint.
INSTALL a new gearshift lever.
Grinding or clashing noises when shifting into 3rd gear
Deflected lubrication condition causing early 3rd gear wear
INSTALL a new 3rd speed gear, 3rd/4th gear shiftfork, outer synchronizer ring, inner synchronizer ring, 3rd speed synchronizer cone, 3rd/4th synchronizer assembly.
Symptom Chart - Clutch Condition Possible Sources Action Clutch Slippage
Clutch pedal free play.
Sticking clutch pedal.
Diaphragm springs.
Clutch pressure plate.
Clutch disc facing.
Hardened or oiled clutch disc facing surface.
Flywheel.
Go to Pinpoint Test A .
Clutch Chatter or Shudder
Engine mounts.
Oil on clutch disc facing.
Diaphragm springs.
Clutch pressure plate.
Clutch disc facing.
Flywheel.
Go to Pinpoint Test B .
Clutch Drag
Insufficient brake fluid.
Air in hydraulic system.
Clutch pedal free play.
Diaphragm springs.
Clutch disc.
Clutch disc splines.
Oil on facing.
Go to Pinpoint Test C .
Clutch Pedal Pulsation
Clutch and brake pedal pivot shaft not correctly lubricated.
Flywheel.
Bad springs in pressure plate.
Go to Pinpoint Test D .
Clutch Related Vibrations
Engine component grounding against frame.
Accessory drive belt.
Flywheel bolts.
Flywheel
Imbalanced clutch pressure plate.
Go to Pinpoint Test E .
Hard Shifting
Insufficient brake fluid.
Clutch pedal free play.
Manual transaxle concern.
Go to Pinpoint Test F .
Excessive Noise
Clutch pedal free play.
Clutch release bearing.
Poor lubrication of clutch release bearing.
Pilot bearing.
Excessive crankshaft end play.
Go to Pinpoint Test G .
Fluid Leakage
Clutch master cylinder.
Clutch slave cylinder.
Clutch hydraulic tubes.
Go to Pinpoint Test H .
by the way - check fluid level in clutch master cylinder and bleed if necessary to remove air, check for leaks.
The MTX-75 manual transmission is equipped with a cable gearshift mechanism on the Contour/Mystique.
The shift cable is white and the selector cable is black.
In order to disconnect the cables from their brackets on the transmission and at the gear lever, twist the two halves of each bracket counterclockwise against each other.
Because they are jointly connected to the floor assembly, the selector and shift cables may only be installed newly as a pair. 
Item Part Number Description 1 - Gearshift lever 2 - Shift cable 3 - Selector cable 4 - Gear selector lever on the transmission 5 - Gearshift lever on the transmission 6 - Cable guide
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SOURCE: wheel bearing ford contour
this comes a a hub assembly
you need to remove the brakes and brake rotor
the center nut holding in your CV shaft
in the hub you will find holes that you can put your socket threw to remove the mounting bolts.
SOURCE: ford contour
Check your timing belt by carefully removing the timing belt pulley cover to the left of the valve cover. The valve cover houses the spark plugs. You should be able to flash a flashlight down and see your timing belt. Most likely, you have a timing belt going, or a shaving stuck in your VCT solenoid. I'm guessing the belt is worn and has slipped a tooth or two. I would take caution driving it as it's been disputed that it could be an interference engine, and you could do serious damage to your vehicle.
SOURCE: 1998 ford contour
I encountered this same problem and the solution is rather uncomfortable for any normal sized human. You will actually have to get on your back and look straight up under the dash (not a comfortable position) just a little forward from where your left knee would be when driving. If you can set up a low table or some other solid object just outside the driver's door about the same height as the kick panel this will be helpful to ease discomfort while accessing the fuse box. You will recognize the fuse box as it has a diagram of the fuse locations on the outside of the box. You will probably need a flat head screwdriver to push the tab which opens the box. Good luck and hope this helps.
SOURCE: 1998 ford contour fuse diagram
dont have an actual diagram but if you check at mastercraft.com they have a copy of the owners manual online and its free to access.
SOURCE: need a diagram for serpentine belt 1998 Ford Contour 4cyl 2.0l.
98 ford contour 2.0 belt routing
here is a picture of routing and how to do it , etc. , good resource ..
J5
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