Manual Gearbox Faults
(1) Hard shifting of gears.
(2) Transmission sticks in gear.
(3) Transmission slips out of gear.
(4) Gear clash during shifting.
(5) Transmission noisy in neutral.
(6) Transmission noisy in gear.
(7) No power output through transmission.
(8) Gear oil leaking.
(1) Hard shifting of gears.
Possible Causes :
1. Gear shift mechanism lacks lubrication.
2. Gear shift linkage out of adjustments.
3. Clutch mis-adjusted.
4. Excessive clutch pedal free play.
5. Gear shifter fork bent.
6. Sliding gear wheels or synchronizing unit stuck on shaft splines.
7. Synchronizing unit or splines damaged.
8. Gear teeth damaged.
9. Gear cable not properly lubricated.
10. Use of thicker gear oil than recommended.
(2) Transmission sticks in gear.
Possible Causes :
1. Gear shift mechanism lacks lubrication.
2. Gear shift linkage out of adjustment or disconnected.
3. Clutch not disengaging.
4. Synchronizing unit stuck.
5. Lock-outs stuck.
6. Internal gear shifter components damaged.
7. Insufficient lubricant in gear box.
8. Incorrect type of lubricant in gear box.
(3) Transmission slips out of gear.
Possible Causes :
1. Gear shift linkages out of adjustments.
2. Gear box bearings or gears worn
3. Weak lock out springs.
4. Excessive end play of shafts or gear wheels.
5. Synchronizer unit worn or defective.
6. Gear box misaligned with clutch plate.
7. Gear box loose on clutch housing.
8. Crankshaft pilot bushing loose or broken.
9. Broken engine mount.
(4) Gear clash during shifting.
Possible Causes :
1. Clutch not disengaging (Pedal free play incorrect)
2. Synchronizer unit defective.
3. Engine idle speed excessive.
4. Pilot bush binding.
5. Gear shift linkage out of adjustment.
6. Incorrect type of gear lubricant.
7. Hydraulic system defective (Hydraulic Clutch)
(5) Transmission noisy in neutral.
Possible Causes :
1. Input shaft bearing worn, defective or fouled.
2. Gears worn or teeth broken.
3. Pilot bushing worn or loose on crankshaft.
4. Transmission misaligned with engine.
5. Counter shaft worn, bent or washers damaged.
(6) Transmission noisy in gear.
Possible Causes :
1. Rear main bearing worn or dry.
2. Loose gear wheels on main shaft.
3. Synchronizers worn or damaged.
4. Speedometer gear damaged.
5. Incorrect grade or insufficient lubricant.
6. Defective clutch friction disc.
7. Any condition caused noisy transmission in neutral.
(7) No power output through transmission.
Possible Causes :
1. Clutch slipping.
2. Gear or shaft broken.
3. Drive keys or splines sheared off.
4. Gear teeth stripped off.
5. Shift fork or other linkage broken.
(8) Gear oil leaking.
Possible Causes :
1. Excessive amount of gear lubricants.
2. Foaming due to incorrect grade of lubricant.
3. Damaged or missed gasket.
4. Oil seals improper, worn, damaged or missing.
5. Drain plug loose.
6. Gear box cover loose.
7. Gear box cracked.