Manual Transmission

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GENERAL DIAGNOSTIC CHART - MANUAL TRANSMISSION

Symptom	Possible cause	Remedy
1. Gears are difficult to intermesh. NOTE: The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the other is malfunction of the transmission. However, if the operation is heavy and engagement of the gears is difficult, defective clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and transmission.	(a) Worn, damaged or burred chamfer of internal spline of sleeve and reverse driven gear	Replace.
	(b) Worn, damaged or burred chamfer of spline of gears	Replace.
	(c) Worn or scratched bushings	Replace.
	(d) Incorrect contact between synchronizer ring and gear cone or wear	Correct or replace.
2. Gear slips out. Gear slips out when coasting on rough road. Gear slips out during acceleration.	(a) Defective pitching stopper adjustment	Adjust.
	(b) Loose engine mounting bolts	Tighten or replace.
	(c) Worn fork shifter, broken shifter fork rail spring	Replace.
	(d) Worn or damaged ball bearing	Replace.
	(e) Excessive clearance between splines of synchronizer hub and synchronizer sleeve	Replace.
	(f) Worn tooth step of synchronizer hub (responsible for slip-out of 3rd gear)	Replace.
	(g) Worn 1st driven gear and driven shaft	Replace.
	(h) Worn 2nd driven gear and bushing	Replace.
	(i) Worn 3rd drive gear and needle bearing	Replace.
	(j) Worn 4th drive gear and needle bearing	Replace.
	(k) Worn reverse idler gear and bushing	Replace.
3. Unusual noise comes from transmission. NOTE: If an unusual noise is heard when the vehicle is parked with its engine idling and if the noise ceases when the clutch is disengaged, it may be considered that the noise comes from the transmission.	(a) Insufficient or improper lubrication	Lubricate or replace with specified oil.
	(b) Worn or damaged gears and bearings NOTE: If the trouble is only wear of the tooth surfaces, merely a high roaring noise will occur at high speeds, but if any part is broken, rhythmical knocking sound will be heard even at low speeds.	Replace.