Manual Transmission/Transaxle: Testing and Inspection

DIAGNOSIS AND TESTING - COMMON PROBLEM CAUSES
The majority of transaxle malfunctions are a result of:
- Insufficient lubrication
- Incorrect lubricant
- Misassembled or damaged internal components
- Improper operation

HARD SHIFTING
Hard shifting may be caused by a misadjusted crossover cable. If hard shifting is accompanied by gear clash, synchronizer clutch and stop rings or gear teeth may be worn or damaged.

Misassembled synchronizer components also cause shifting problems. Incorrectly installed synchronizer sleeves, struts, or springs can cause shift problems.

NOISY OPERATION
Transaxle noise is most often a result of worn or damaged components. Chipped, broken gear or synchronizer teeth, and brinnelled, spelled bearings all cause noise.

Abnormal wear and damage to the internal components is frequently the end result of insufficient lubricant.

SLIPS OUT OF GEAR
Transaxle disengagement may be caused by misaligned or damaged shift components, or worn teeth on the drive gears or synchronizer components. Incorrect assembly also causes gear disengagement.

LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the result of leaks, or inaccurate fluid level check or refill method. Leakage is evident by the presence of oil around the leak point. If leakage is not evident, the condition is probably the result of an underfill.

If air-powered lubrication equipment is used to fill a transaxle, be sure the equipment is properly calibrated. Equipment out of calibration can lead to an underfill condition.

CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components can cause difficult shifting, gear clash, and noise.

A worn or damaged clutch disc, pressure plate, or release bearing can cause hard shifting and gear clash.