If your car is still under warrenty you stand a chance. If you are out of warrenty you are on your own unless you have a very friendly service manager that will step up and help you out. You need to reference this Tecnical Service Bulletin (TSB's are not recalls they are information to the dealers from Ford about common problems and Ford's cure for them IF THE CUSTOMER COMPLAINS)
You need to read the TSB very carefully and make sure when you go to the dealer you ONLY complain about the problems covered by the TSB (Noise, rattling etc) if you just complain about a slipping clutch they will call it a wear item and not cover it. If they have to replace the flywheel to cure the noise problem they will also have to replace the clutch with the updated unit (the old one will not fit on the new flywheel) so you would get a new clutch out of the deal.
TSB 04-21-19 TRANSAXLE NOISE AT IDLE IN NEUTRAL WITH CLUTCH PEDAL RELEASED - PREMATURE CLUTCH WEAR
Publication Date: October 20, 2004
FORD: 2002-2004 Focus
This article supersedes TSB 04-12-02 to update the service procedure.
ISSUE:
Some 2002-2004 SVT Focus vehicles may exhibit premature clutch wear, or a clunking and rattling noise in the transaxle, mainly at idle in neutral. The noise can typically be reduced by fully depressing the clutch pedal. The premature clutch wear or noise may be caused by the dual mass flywheel, clutch disc, pressure plate or by transaxle alignment.
ACTION:
Refer to the following Service Procedure.
SERVICE PROCEDURE
Check transaxle fluid level. If low, fill to correct level and retest for noise and proper clutch operation. If noise is still present or clutch is not operating properly proceed to Step 2.
Remove the transaxle. Refer to Workshop Manual Section 308-03C: Manual Transaxle/Transmission - MT285; Removal.
Inspect the clutch slave cylinder assembly as follows:
Inspect for leaks.
Rotate the outer race, while applying pressure and check for roughness.
Inspect for any surface scoring or burrs that may impede the sliding motion of the clutch release hub and bearing. Scoring or burrs should be polished off with a fine grade of emery paper.
Replace the clutch slave cylinder if necessary. Refer to Workshop Manual Section 308-02B: Clutch Controls - MT285/MTX75 Transaxle - Clutch Slave Cylinder.
Inspect the transaxle input shaft for damage, spline wear, burrs or rough surfaces. Scoring or burrs should be polished off with a fine grade of emery paper. Replace the transaxle if the input shaft is damaged and cannot be repaired.
NOTE: IT IS NORMAL FOR THE INPUT SHAFT TO APPEAR POLISHED WHERE THE CLUTCH HUB SEATS, NO ACTION IS REQUIRED UNLESS THE SPLINES ARE DAMAGED OR WORN.
Remove the clutch disc, pressure plate and flywheel. Refer to Workshop Manual Section 308-01C; Clutch - MT285 Transaxle - Removal and Installation - Clutch Disc and Pressure Plate.
Inspect the rear face of the engine block as follows:
Ensure that the two (2) required engine dowel pins are installed and are not damaged. If the dowel pins are missing or damaged replace as required.
Inspect the corresponding dowel pin holes on the transaxle. It is acceptable for the dowel pin holes to bear slight witness marks from a tight fitting dowel. However, if the holes are elongated then they must be measured. If elongation is greater than 0.040" (1.02 mm) out-of-round replace the transaxle.
Inspect the upper and lower separator plates for damage or warping. Replace if needed.
Inspect the crankshaft flange and flywheel mating surface for residual thread locking compound or rust. Clean as necessary.
Install the following new revised components:
NOTE: THE REVISED FLYWHEEL, CLUTCH DISC AND PRESSURE PLATE ARE NOT COMPATIBLE WITH PRODUCTION LEVEL CLUTCH COMPONENTS. DO NOT INTERCHANGE OR MIX.
Revised dual mass flywheel and new flywheel retaining bolts. Torque bolts in sequence to 83 lb-ft (112 N-m).
Revised pressure plate and clutch disc, and new clutch pressure plate retaining bolts. Ensure the clutch disc is properly installed with "TRANS SIDE" label facing the pressure plate. Tighten pressure plate bolts two (2) turns at a time in sequence and torque to 21 lb-ft (29 N-m).
Install transaxle. Torque the transaxle bolts in sequence to 35 lb-ft (48 N-m) to ensure proper transaxle to engine block alignment. Refer to the appropriate model year Workshop Manual Section 308-03C; Manual Transaxle/Transmission - MT285 - Installation.
NOTE: THE TRANSAXLE BOLTS COME IN FOUR (4) UNIQUE LENGTHS AND WILL FIT INTO ANY OF THE THROUGH HOLES OF THE TRANSAXLE TO ENGINE BLOCK. IT IS CRITICAL THAT THE PROPER LENGTH BOLT IS INSTALLED INTO ITS PROPER MATING HOLE.
PART NUMBER PART NAME
2M5Z-7002-BD Transaxle
2M5Z-7A564-AA Slave Cylinder
4M5Z-7550-AA Clutch Disk
4M5Z-7563-AA Pressure Plate
3S4Z-6477-AA Flywheel
W702426-S303 Bolt - Pressure Plate
W707339-S430 Bolt - Flywheel
W701350-S309 Dowel Pins
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
BASIC PART NO. CONDITION CODE
7563 D4
