Inspection and Verification

Manual Transmission and Clutch

Inspection and Verification

NOTICE: If transmission noise is reported, first check the fluid level. The vehicle should not be driven if the fluid level is low. A low fluid level will damage the transmission.

NOTE: Before attempting to repair any concerns, road test the vehicle to determine which system the concern is in.

NOTE: If an observed or reported concern is found, correct the cause (if possible) before proceeding.

Gear driven units produce a certain level of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions. Many conditions, such as road and weather, will amplify normal vehicle noise.

The following overview is a guide to diagnose a transmission or clutch concern:

- Verify and document the customer concern.
- During the customer interview, if a leak was noticed or if a leak is the concern, check the transmission fluid. The vehicle should not be driven if the fluid level is low.

- Check fluid level and condition.
- Evaluate the clutch hydraulic system.
- Evaluate the clutch.
- Inspect gearshift mechanism.
- Evaluate the transmission.
- Find the cause of the problem and correct it.

Verify Customer Concern

1. Verify and document the customer concern.

1. When was it first noticed?

2. Did it appear suddenly or gradually?

3. Did anything unusual occur that would coincide with it or precede it?

4. Identify when the condition occurs:
- Hot or cold vehicle operating conditions.

- Type of terrain.

- City/highway driving.

- Driving at a particular speed.
- coasting.

- hard acceleration.

- Shifting.
- upshifts.

- downshifts.

- in a particular gear.

- in all gears.

- Hot or cold ambient temperatures.

5. Has the transmission/clutch been repaired before or components installed?
- Check the vehicle service record. Note any repairs.

Check Fluid Level and Condition

NOTICE: The vehicle should not be driven if the fluid level is low or damage may occur.

NOTICE: Excessive temperatures may break down the transmission lubricant. If there is reason to believe that the transmission has been subjected to temperatures exceeding 135°C (275°F) for an extended period (greater than 20 minutes), change the lubricant immediately.

An incorrect level may affect the transmission operation and can result in transmission damage. To correctly check and add fluid to the transmission, refer to the Material chart.

A low fluid level can result in poor transmission shifting, engagement or damage. It can also indicate a leak in one of the transmission seals or gaskets.

1. Check the fluid condition.
- Observe the color and the odor of the fluid. Allow the fluid to drip onto a white cloth and examine the stain. Check the fluid for contamination or metal particles.
- Fluid should appear reddish in color for the TR6060.

- Fluid should appear amber to dark amber in color for the MT82.

Evaluate Clutch Hydraulic System

1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
- If the fluid level is correct, proceed to clutch check.

- If the fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks and repair as necessary.

Evaluate the Clutch

1. Apply and release the clutch pedal slowly to check if the pedal is binding. Make sure the clutch pedal can be fully applied and is not restricted by the floor mat.

2. Measure the clutch reserve. GO to Pinpoint Test C. Pinpoint Test C: Clutch Pedal Feels Spongy Or Has Excessive Travel/Clutch Will Not Disengage/Clutch System Leakage

3. With the engine idling and the park brake applied, move the gearshift lever into 4th gear. Increase engine speed to 2,000 rpm and slowly release the clutch pedal.
- If the engine stalls, clutch is OK.

- If the engine does not stall, clutch is slipping. Repair as necessary.

4. Compare the clutch evaluation results with the following table. The following list of conditions are typical clutch concerns.

Symptom Chart - Transmission Operation