Manual Transaxle Symptom Diagnosis

MANUAL TRANSAXLE SYMPTOM DIAGNOSIS

Condition	Possible Cause	Action
Gears slipping out of mesh	Worn shift fork shaft	Replace shift fork shaft: See GEAR SHIFT SHAFT AND FORK COMPONENTS .
	Worn shift fork or synchronizer sleeve	Replace shift fork or synchronizer sleeve . Shift fork: See GEAR SHIFT SHAFT AND FORK COMPONENTS . Input shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
	Weak or damaged gear locating springs	Replace gear locating spring: See GEAR SHIFT AND SELECT SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
	Worn bearings on input shaft or countershaft	Replace input shaft bearing or countershaft bearing . Input shaft bearing: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft bearing: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
	Worn chamfered tooth on sleeve and gear	Replace synchronizer sleeve and gear . Input Shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
Hard shifting	Inadequate lubricant	Replenish manual transaxle oil: See MANUAL TRANSAXLE OIL CHANGE .
	Improper clutch pedal free travel	Replace clutch operating cylinder or master cylinder Clutch operating cylinder: See CLUTCH OPERATING CYLINDER ASSEMBLY REMOVAL AND INSTALLATION . Clutch master cylinder: See CLUTCH MASTER CYLINDER REMOVAL AND INSTALLATION .
	Distorted or broken clutch disc	Replace clutch disc: See CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION .
	Damaged clutch pressure plate	Replace clutch cover: See CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION .
	Worn synchronizer ring	Replace synchronizer ring . Input Shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
	Worn chamfered tooth on sleeve or gear	Replace synchronizer sleeve and gear . Input Shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
	Worn select lever bush	Replace select lever bushing: See GEAR SHIFT AND SELECT SHAFT ASSEMBLY COMPONENTS .
	Distorted shift shaft	Replace shift shaft: See GEAR SHIFT SHAFT AND FORK COMPONENTS .
	Broken gear shift/select control cables	Replace gear shift and select cable: See GEAR SHIFT CONTROL LEVER AND CABLE REMOVAL AND INSTALLATION .
Noise	Inadequate or insufficient lubricant	Replenish manual transaxle oil: See MANUAL TRANSAXLE OIL CHANGE .
	Damaged or worn bearing(s)	Replace bearing . Input Shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
	Damaged or worn gear(s)	Replace gear . Input Shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .
	Damaged or worn synchronizer parts	Replace synchronizer parts . Input Shaft: See INPUT SHAFT DISASSEMBLY AND REASSEMBLY . Countershaft: See COUNTERSHAFT DISASSEMBLY AND REASSEMBLY .