Symptom Chart

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SYMPTOM CHART - TRANSAXLE

Condition	Possible Sources	Action
Noisy in forward gears - While verifying the condition, determine whether the noise is a gear roll over noise, release bearing rub or some other transmission-related noise. Gear roll over noise, inherent in manual transmissions, is caused by the constant mesh gears turning at the engine idle speed while the clutch is engaged and the transmission is in NEUTRAL. Gear roll over noise will disappear when the clutch is disengaged or when the transmission is engaged in gear. Release bearing rub is sometimes mistaken for mainshaft bearing noise. Release bearing rub will disappear when the clutch is engaged. In the event that a bearing is damaged, the noise is more pronounced while engaged in gear under load or coast than in NEUTRAL.	Lubricant	ADD specified lubricant as necessary.
	Components grounding out on the transmission	CHECK for screws, bolts or other components grounding out. CORRECT as required.
	Component housing bolts	CHECK the torque on the transmission-to-clutch housing bolts and the clutch housing-to-engine block bolts. TIGHTEN the bolts to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Bearings or gears	INSPECT the bearings. INSPECT the gears and gear teeth for wear or damage. INSTALL new components as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION .
Gears clash when shifting from one forward gear to another	Clutch not fully releasing	INSPECT clutch release mechanism for correct operation. CHECK the clutch pedal freeplay. REFER to CLUTCH PEDAL FREEPLAY ADJUSTMENT .
	Transmission input shaft pilot bearing worn/damaged	INSPECT the transmission input shaft pilot bearing for wear and damage. REPAIR as necessary.
	Gear teeth and/or synchronizer	REPAIR or INSTALL new components as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Engine idle speed too high	REFER to the INTRODUCTION - GASOLINE article.
Transmission jumps out of gear	Excessive gearshift lever boot tension	INSTALL a new gearshift lever boot and knob assembly. REFER to MANUAL TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
	Transmission-to-engine mounting bolts	TIGHTEN the transmission-to-engine block bolts to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Internal components	INSPECT the synchronizer sleeves for free movement on their hubs. INSPECT the synchronizer blocking rings for widened index slots, rounded clutch teeth and a smooth internal surface. CHECK the countershaft cluster gear for excessive end play. CHECK the shift forks for worn or loose mounting on the shift rails. INSPECT the synchronizer sliding sleeve and the gear clutch teeth for wear or damage. REPAIR or INSTALL new components as necessary.
	Gear teeth worn or damaged	INSTALL new gears. REFER to MANUAL TRANSAXLE/TRANSMISSION .
Transmission will not shift into one gear - all others OK	Manual shifting components	REPAIR or INSTALL new components as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION EXTERNAL CONTROLS .
	Reversing lamp switch ball	If REVERSE is the problem, CHECK the reversing lamp switch for the ball frozen in the extended position.
	Internal components	INSPECT the shift rail and fork system, the synchronizer system and the gear clutch teeth for restricted travel. REPAIR or INSTALL new components as necessary.
Transmission is locked in one gear and cannot be shifted out of that gear	Internal components	INSPECT the problem gears, the shift rails, the forks and the synchronizer for wear or damage. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Fork on rail	CHECK the shift rail interlock system. REFER to MANUAL TRANSAXLE/TRANSMISSION .
Transmission leaks	Lubricant	CHECK the fluid level and type.
	Other components leaking	IDENTIFY the leaking fluid as engine, power steering or transmission fluid. REPAIR as required. REMOVE all traces of fluid on exposed transmission surfaces. CHECK the vent for free breathing. OPERATE the transmission and INSPECT for new leakage. REPAIR as necessary.
	Internal components	INSPECT for leaks at the input shaft bearing retainer seal and the shift rail expansion plug. REFER to MANUAL TRANSAXLE/TRANSMISSION . INSPECT for leaks at the transaxle case-to-clutch housing seam. INSPECT the case for sand holes or cracks. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Fill and drain plugs	CHECK the fill plug, the drain plug and the bore threads. REPAIR as necessary. TIGHTEN to specification. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Transmission case bolt	CHECK for loose or missing bolts. REPAIR as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Halfshaft oil seals	CHECK for cracked, loose or damaged RH intermediate shaft oil seal or LH halfshaft oil seal. REPLACE as necessary. REFER to MANUAL TRANSAXLE/TRANSMISSION .
Bearing failure	Other part failure Raceways or rollers Lubricant	REMOVE, DISASSEMBLE and CLEAN the transmission, then REPLACE the damaged parts. (It is necessary to RESET the bearing preload if any tapered bearings are replaced.) REFER to MANUAL TRANSAXLE/TRANSMISSION .
	Vibration break-up of retainer and brinelling of races Bearing(s) Shafts or bore Overloading of vehicle Incorrect preload	DETERMINE and CORRECT the cause of the vibration. Otherwise, PROCEED as above.
	Input shaft oil dam	INSTALL new components and verify correct oil dam installation. REFER to MANUAL TRANSAXLE/TRANSMISSION . CHECK for correct installation of the snap ring on the mainshaft next to the oil dam.
	Oil baffle in the input bearing shim pack	INSTALL new components. MAKE SURE the oil baffle is not damaged during reassembly. REFER to MANUAL TRANSAXLE/TRANSMISSION .