Symptom Chart

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

MANUAL TRANSMISSION, CLUTCH & TRANSFER CASE SYMPTOM

Condition	Possible Sources	Action
Clutch Slippage	Clutch Pedal Sticking. Pressure Plate Diaphragm Spring Damaged Or Weakened. Clutch Pressure Plate Damaged. Clutch Disc Facing Damaged Or Worn Excessively. Clutch Disc Facing Surface Hardened Or Oil Coated. Clutch Release Hub & Bearing Binding. Flywheel Glazed Or Damaged.	Go To PINPOINT TEST A: CLUTCH SLIPPAGE .
Clutch Chatter Or Shudder	Engine/Transmission Mount Loose Or Damaged. Oil On Clutch Disc Facing. Clutch Pressure Plate Damaged Or Excessive Runout. Clutch Disc Facing Surface Hardened Or Damaged. Flywheel Surface Glazed Or Damaged. Transmission Input Shaft Eccentric Or Not Perpendicular. Pilot Bearing Worn Or Damaged.	Go To PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER .
Clutch Pedal Feels Spongy Or Has Excessive Travel. Clutch Will Not Disengage	Insufficient Clutch System Fluid. Leakage Of Clutch System Fluid. Air In Hydraulic System.	Go To PINPOINT TEST C: CLUTCH HYDRAULIC SYSTEM CHECK .
Clutch Drag, Also Hard To Shift	Insufficient Clutch System Fluid. Leakage Of Clutch System Fluid. Air In Hydraulic System. Excessive Runout Or Damaged Clutch Disc. Clutch Disc Splines Rusted Or Worn. Pilot Bearing Worn Or Damaged.	Go To PINPOINT TEST D: CLUTCH DRAG .
Clutch Pedal Pulsation	Clutch Disc Damaged Or Worn. Excessive Flywheel Runout.	Go To PINPOINT TEST E: CLUTCH PEDAL PULSATION .
Clutch Related Vibrations	Engine Component Grounding Against Frame. Loose Flywheel Bolts. Excessive Flywheel Runout. Imbalanced Clutch Pressure Plate. Accessory Drive Belt Loose Or Damaged. Pilot Bearing Worn Or Damaged.	Go To PINPOINT TEST F: CLUTCH RELATED VIBRATIONS .
Binding - Difficult Shift Lever Movement	Manual Transmission Concern.	Go To PINPOINT TEST G: BINDING - DIFFICULT SHIFT LEVER MOVEMENT .
Excessive Noise	Clutch Slave Cylinder Assembly. Pilot Bearing Worn Or Damaged. Excessive Crankshaft End Play. Clutch Pressure Plate & Disc.	Go To PINPOINT TEST H: EXCESSIVE NOISE .
Transmission Difficult To Shift - Grinding Noise When Shifting	Insufficient Clutch Hydraulic Fluid.	ADD Or INSTALL New With Specified Lubricant.
	Internal Shift Mechanism.	CHECK The Internal Shift Mechanism For A Smooth Operation. REPAIR Or INSTALL New As Required.
	Sliding Gears &/Or Synchronizers.	CHECK For Free Movement Of Gears & Synchronizers. REPAIR Or INSTALL New As Required.
	Housings &/Or Shaft.	CHECK For Binding Condition Between The Input Shaft & The Engine Crankshaft Pilot Bearing Or Bushing. REPAIR or INSTALL New As Required. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Air In Clutch Hydraulic System.	Go To PINPOINT TEST C: CLUTCH HYDRAULIC SYSTEM CHECK .
NOTE: While Verifying The Condition, Determine Whether The Noise Is 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 & The Transmission Is In NEUTRAL. Release Bearing Rub Is Sometimes Mistaken For Mainshaft Bearing Noise. Gear Roll Over Noise Will Disappear When The Clutch Is Disengaged Or When The Transmission Is Engaged In Gear. 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. Noisy In Forward Gears	Lubricant.	ADD With Specified Lubricant As Necessary.
	Components Grounding Out On The Transmission.	CHECK For Screws, Bolts, Etc., Of Cab Or Other Components Grounding Out. CORRECT As Required.
	Components Housing Bolts.	CHECK the Torque On The Transmission-To-Flywheel Housing Bolts & The Flywheel Housing-To-Engine Block Bolts. TIGHTEN The Bolts To Specification. Refer To CLUTCHES .
	Bearings Or Gears.	INSPECT The Bearings. INSPECT The Gears & Gear Teeth For Wear Or Damage. INSTALL New Components As Necessary. Refer To CLUTCHES .
Gears Clash When Shifting From One Forward Gear To Another	Pilot Bearing.	CHECK For A Binding Condition Between The Input Shaft & The Engine Crankshaft Pilot Bearing. INSTALL New As Required. Refer To CLUTCHES article .
	Gear Teeth &/Or Synchronizer.	REPAIR Or INSTALL New Components As Necessary. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Engine Idle Speed Too High.	REFER To The TROUBLE SHOOTING - NO CODES - EEC-V - GASOLINE & NGV article .
Transmission Jumps Out Of Gear	Gearshift Lever Boot.	INSTALL A New Gearshift Lever Boot If Exceptionally Stiff. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Transmission-to-Engine Mounting Bolts.	TIGHTEN The Transmission-To Engine Block Bolts To Specification.
	Crankshaft Pilot Bearing.	INSTALL A New Bearing.
	Interior Components Damage.	INSPECT The Synchronizer Sleeves For Free Movement On Their Hubs. INSPECT the Synchronizer Blocking Rings For Widened Index Slots, Rounded Clutch Teeth & Smooth Internal Surface. CHECK countershaft Cluster Gear For Excessive End Play. CHECK Shift Forks For Worn Or Loose Mounting On Shift Rails. INSPECT The Synchronizer Sliding Sleeve & 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 Linkage.	REPAIR Or INSTALL New Components As Necessary.
	Backup Switch Ball.	If REVERSE Is The Problem, CHECK backup Switch For Ball Frozen In Extended Position.
	Internal Components.	INSPECT The Shift Rail & Fork System, Synchronizer System & The Gear Clutch Teeth For Restricted Travel. REPAIR Or INSTALL New Components As Necessary.
Transmission Is Locked In One Gear & Cannot Be Shifted Out Of That Gear	Internal Components.	INSPECT The Problem Gears, Shift Rails, Forks & The Synchronizer For Wear Or Damage. REPAIR As Required. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Fork On Rail.	CHECK The Shift Rail Interlock System. Refer To MANUAL TRANSAXLE/TRANSMISSION .
Transmission Leaks	Lubricant.	CHECK The Level & Type.
	Other Component Leaking.	IDENTIFY Leaking Fluid As Engine, Power Steering, Or Transmission Fluid. REPAIR As Required. REMOVE All Traces Of Lube On Exposed Transmission Surfaces. CHECK Vent For Free Breathing. OPERATE The Transmission & INSPECT For New Leakage. REPAIR As Required. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Internal Components.	INSPECT For Leaks At The Input Shaft Bearing Retainer Seal & The Shift Rail Expansion Plug. Refer To MANUAL TRANSAXLE/TRANSMISSION . INSPECT For Leaks At The Top Cover Gasket. INSPECT The Case For Sand Holes Or Cracks. REPAIR As Required. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Fill & Drain Plugs.	CHECK Fill, Drain Plugs & Bore Threads. REPAIR As Necessary. TIGHTEN To Specified Torque Value. Refer To MANUAL TRANSAXLE/TRANSMISSION .
	Transmission Case Bolt.	CHECK For Loose Or Missing Bolts. REPAIR As Necessary. Refer To MANUAL TRANSAXLE/TRANSMISSION .
Noise From Transfer Case	Tires & Wheels.	MAKE Sure That All Tires & Wheels Are The Same Size & That The Inflation Pressures Are Correct.
	Tire Tread.	CHECK for Tire Wear To See If There Is More Than 1.5 mm (0.06 inch) Difference In The Tread Wear Between The Front & Rear.
	Internal Components.	If There Is Noise In All Gears, OPERATE The Vehicle In All Transfer Case Ranges, If Noisy In All Ranges, CHECK Input Shaft, Planetary Assembly, Sprockets, Chain & Single Cardan U-Joint For Damages. INSTALL New U-Joints As Necessary.
Transfer Case Jumps Out Of Gear	Shift Linkage.	CHECK For Interferences To The Shift Boot & Body.
	Mounting Bolts.	TIGHTEN The Mounting Bolts.
	Front & Rear Driveshaft Slip-Yokes.	LUBRICATE & REPAIR Slip-Yokes As Required.
	Internal Components.	CHECK the Input Shaft, Planetary Gear Assembly, Sliding Shift Collar Hubs & Detent Spring For Damage. INSTALL New Components As Necessary. Refer To MANUAL TRANSAXLE/TRANSMISSION .
Other Part Failure. Raceways Or Rollers. Lubricant. Towing Vehicle Further Than 80 km (50 miles) With Driveshaft Installed. Mainshaft Tapered Bearing & Needle Caged Bearings Are Especially Susceptible To Damage.		REMOVE, DISASSEMBLE & CLEAN the Transmission, Then REPLACE The Damaged Parts. (Necessary To RESET The Bearing Preload If Any Tapered Bearings Are Replaced). Refer To MANUAL TRANSAXLE/TRANSMISSION .
Vibration Break-Up Of Retainer & Brinelling Of Races. Bearing(s). Shafts Or Bore. Overloading Of Vehicle. Incorrect Preload.	DETERMINE The Cause Of Vibration & CORRECT. Otherwise PROCEED As Above.
Input Shaft Oil Dam.	INSTALL New Components & Make Sure Of 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 Making Sure The Oil Baffle Is Not Damaged During Reassembly. Refer To MANUAL TRANSAXLE/TRANSMISSION .