Manual Transaxle Symptom Diagnosis
WARNING: This page is about a different car, the 2010 Suzuki Kizashi. However, it is still accessible from the selected car via links, so may be relevant.
MANUAL TRANSAXLE SYMPTOM DIAGNOSIS CHART
| 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: Gear Shift Shaft and Fork Components Input shaft: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: 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: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft bearing: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |
|
| Worn chamfered tooth on sleeve and gear | Replace synchronizer sleeve and gear
. Input shaft: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |
|
| Hard shifting | Insufficient 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: CLUTCH OPERATING CYLINDER ASSEMBLY REMOVAL AND INSTALLATION Clutch master cylinder: 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: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |
|
| Worn chamfered tooth on sleeve or gear | Replace synchronizer sleeve and gear
. Input shaft: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |
|
| Worn select lever bushing | Replace select lever bushing . | |
| 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 | Insufficient lubricant | Replenish manual transaxle oil, see Manual Transaxle Oil Change . |
| Damaged or worn bearing(s) | Replace bearing. Input shaft: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |
|
| Damaged or worn gear(s) | Replace gear
. Input shaft: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |
|
| Damaged or worn synchronizer parts | Replace synchronizer parts
. Input shaft: INPUT SHAFT DISASSEMBLY AND REASSEMBLY Countershaft: COUNTERSHAFT DISASSEMBLY AND REASSEMBLY |