Complaint/Condition
| Possible Cause
| correction
|
Knock at Low Speeds
|
| • | Worn side gear or pinion gear bores |
|
| • | Inspect drive axle joint and replace if necessary. |
| • | Inspect differential case and replace if necessary. |
|
Noisy Around Turns
| Worn differential gears
| Inspect differential gears and replace if necessary.
|
Clunk or Acceleration or Deceleration
|
| • | Worn inboard drive axle joint |
| • | Worn differential pinion shaft |
| • | Worn side gear hub counterbore |
|
| • | Inspect engine mounts and tighten if necessary. |
| • | Inspect inboard drive axle joint and replace if necessary. |
| • | Inspect differential pinion shaft and replace if necessary. |
| • | Inspect side gear hub counterbore and replace if necessary. |
|
Click Noise On Turns
| Worn outboard drive axle C/V joint
| Inspect C/V joint and replace if necessary.
|
Noisy in Neutral With Engine Running
|
| • | Worn input gear bearing |
| • | Worn speed gear bearing |
|
| • | lnspect bearing and replace if necessary. |
| • | lnspect bearing and replace if necessary. |
| • | lnspect bearing race and replace if necessary. |
|
Noisy in First Gear Only
|
| • | Worn, chipped, or scored 1st speed constant-mesh gears |
| • | Worn, shipped, or scored 1st/2nd synchroniser |
|
| • | lnspect gears and replace if necessary. |
| • | lnspect synchroniser and replace if necessary. |
|
Noisy in Second Gear Only
|
| • | Worn, chipped, or scored 2nd speed constant-mesh gears |
| • | Worn, chipped, or scored 1st/2nd synchroniser |
|
| • | lnspect gears and replace if necessary. |
| • | lnspect synchroniser and replace if necessary. |
|
Noisy in Third Gear Only
|
| • | Worn, chipped, or scored 3rd speed constant-mesh gears |
| • | Worn, chipped, or scored 3rd/4th synchroniser |
|
| • | lnspect gears and replace if necessary. |
| • | lnspect synchroniser and replace if necessary. |
|
Noisy in Fourth Gear Only
|
| • | Worn, chipped, or scored 4th speed constant-mesh gears |
| • | Worn, chipped, or scored 3rd/4th synchroniser |
| • | Worn, chipped, or scored output gear |
| • | Worn, chipped, or scored output gear |
|
| • | lnspect gears and replace if necessary. |
| • | lnspect synchroniser and replace if necessary. |
| • | lnspect gear and replace if necessary. |
| • | lnspect gear and replace if necessary. |
|
Noisy in Fifth Gear Only
|
| • | Worn, chipped, or scored 5th speed constant-mesh gears |
| • | Worn, chipped, or scored 5th synchroniser |
| • | Worn, chipped, or scored output gear |
|
| • | lnspect gears and replace if necessary. |
| • | lnspect synchroniser and replace if necessary. |
| • | lnspect gear and replace if necessary. |
|
Noisy in Reverse Only
|
| • | Worn, chipped, or scored reverse speed constant-mesh gears |
| • | Worn or damaged output gear |
|
| • | lnspect gear and replace if necessary. |
| • | lnspect gear and replace if necessary. |
|
Noisy in All Gears
|
| • | Worn or damaged wheel bearings |
| • | Worn, chipped, or scored input/output shaft gear |
| • | Worn output gear bearing |
| • | Loose selector rail guide bolt |
| • | Worn, chipped, or scored 1st, 2nd, 3rd, 4rd, 5th, or Reverse gears. |
|
| • | Add fluid to proper level. |
| • | Inspect wheel bearing and replace if necessary. |
| • | Inspect gear and replace if necessary. |
| • | Inspect output gear bearing and replace if necessary. |
| • | Tighten selector rail guide bolt. |
| • | Inspect components and replace as necessary. |
|
Slips Out of Gear
|
| • | Broken or loose input gear bearing retainer |
| • | Worn or bent selector fork |
| • | Dirty clutch housing and engine |
| • | Manual transaxle internal selector mechanism malfunction |
|
| • | Tighten or replace mounts. |
| • | Inspect cables and replace if necessary. |
| • | Inspect selector fork and replace if necessary. |
| • | Inspect selector fork and replace if necessary. |
| • | Clean clutch housing and engine. |
| • | Inspect seal and replace if necessary. |
| • | Disassemble transaxle, repair as necessary. |
|
Slips Out of Gear While Accelerating
|
| • | Missing or misadjusted first gear thrust bearing or washer |
| • | Worn or damaged fist gear spline lock on 1st/2nd synchroniser |
| • | Worn of damaged second gear spline lock on 1st/2nd synchroniser |
| • | Worn or damaged third gear spline lock on 3rd/4th synchroniser |
| • | Worn or damaged fourth gear spline lock on 3rd/4th synchroniser |
| • | Worn or damaged 5th gear spline lock on the 5th/Reverse synchroniser |
| • | Worn or damaged Reverse gear spline lock on the 5th/Reverse synchroniser |
| • | Worn or damaged 1st, 2nd, 3rd, 4th, 5th or reverse gear spline lock |
| • | Manual transaxle internal selector mechanism malfunction |
|
| • | Inspect bearing and washer and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Inspect spline lock and replace if necessary. |
| • | Disassemble transaxle, repair as necessary. |
|
Slips Out of Gear While Coasting
|
| • | Damaged, worn, or missing selector rails |
| • | Manual transaxle internal selector mechanism malfunction |
|
| • | Inspect selector rails and replace if necessary. |
| • | Disassemble transaxle, repair as necessary. |
|
Fluid Leakage
|
| • | Damaged axle shaft seals |
| • | Poor sealing on selector cover |
| • | Poor sealing between case and clutch housing |
| • | Poor sealing on rear cover |
| • | Poor sealing or loose reverse lamp switch |
| • | Poor sealing or loose vehicle speed sensor |
|
| • | Inspect axle shaft seals and replace if necessary. |
| • | Clear or replace vent cap. |
| • | Replace sealer on selector cover. |
| • | Replace sealer between case and clutch housing and tighten. |
| • | Replace sealant on rear cover and tighten. |
| • | Tighten switch or replace sealant as needed. |
| • | Tighten sensor or replace sealant as needed. |
|
