Manual Transmission/Transaxle: Testing and Inspection
INTRODUCTION TO MANUAL TRANSAXLE DIAGNOSISThe mounting could be incorrect, the oil level may be low, or a component of the transaxle may be faulty in the following conditions: noise or vibration is generated, oil leaks, shifting of the gears is hard or troublesome, or the transaxle jumps out of gear.
MANUAL TRANSAXLE DIAGNOSTIC TROUBLESHOOTING STRATEGY
Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a manual transaxle fault.
1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Inspection Chart for Trouble Symptoms.
4. Verify malfunction is eliminated.
SYMPTOM CHART
SYMPTOM PROCEDURES
Inspection procedure 1
Noise, vibration
DIAGNOSIS
STEP 1. Check whether the transaxle and engine mount is loose or damaged.
If loose or damaged, tighten or replace the part. Then go to Step 7.
If normal, go to Step 2.
STEP 2. Check the end play of the input and output shafts.
If faulty, adjust it. Then go to Step 7.
If normal, go to Step 3.
STEP 3. Check the gears for wear or damage.
If worn or damaged, replace the gears. Then go to Step 7.
If normal, go to Step 4.
STEP 4. Check that the specified oil is Hypoid gear oil SAE 75W - 90W or 75W - 85W conforming to API classification GL-4.
If incorrect, replace the oil. Then go to Step 7.
If correct, go to Step 5.
STEP 5. Check that the oil level is up to the lower edge of the filler plug hole.
If low, refill Hypoid gear oil SAE 75W - 90W or 75W - 85W conforming to API classification GL-4. Then go to Step 7.
If correct, go to Step 6.
STEP 6. Check the idle speed. Refer to Powertrain Management.
After adjusting, go to Step 7.
STEP 7. Check trouble symptoms.
Check that noise and vibration are not generated.
Inspection procedure 2
Oil leaks
DIAGNOSIS
STEP 1. Check the oil seal or O-ring for damage.
If damaged, replace the part. Then go to Step 2.
STEP 2. Check trouble symptoms.
Check that the oil is not leaking.
Inspection procedure 3
Shifting gears is hard or troublesome
DIAGNOSIS
STEP 1. Check the control cable
If faulty, repair or replace. Then go to Step 5.
If normal, go to Step 2.
STEP 2. Check for poor meshing or wear of synchronizer ring and gear cone.
If faulty, repair or replace. Then go to Step 5.
If normal, go to Step 3.
STEP 3. Check the synchronizer spring for weakness.
If weakened, replace the part. Then go to Step 5.
If normal, go to Step 4.
STEP 4. Check that the specified oil is Hypoid gear oil SAE 75W - 90W or 75W - 85W conforming to API classification GL-4.
If incorrect, replace the oil. Then go to Step 5.
STEP 5. Check trouble symptoms.
Check that the shifting of the gears is not hard or troublesome.
Inspection procedure 4
Jumps out of gear
DIAGNOSIS
STEP 1. Check the gear shift forks for wear or the poppet spring for breakage.
If worn or broken, replace the part. Then go to Step 3.
If normal, go to Step 2.
STEP 2. Check the clearance (excessive) between the synchronizer hub and sleeve.
If incorrect, replace the part. Then go to Step 3.
STEP 3. Check trouble symptoms.
Check that the gears do not slip out.