Troubleshooting and remedies of the Transmission system

1. Noisy gearbox operation:

• The bearings may be worn, in which case they will need to be replaced.

• The countershaft can be worn, bent or have a large axial play. This must be replaced with a new countershaft.

• Constant-mesh gears can be worn. The only alternative is their replacement.

• Lack or wrong grade of lubricant. The gearbox must be filled with the specified lubricant.

• The gears can be worn; need to be replaced.

• The gears may be loose on the main shaft. This may be due to worn splines or gears on the main shaft. The worn part must be replaced to remedy the defect.

• The mounting bolts may be loose and may be tightened.

2. Hard shifting:

• The clutch adjustment may be incorrect, which should be correct.

• The clutch connection may be constrained. The same can be repaired or lubricated as needed.

• There may be a misalignment of the clutch housing. The runout at the rear of the clutch housing can be checked and corrected if necessary.

• The main shaft gears may be tightened on the splines. To eliminate the problem, the splines of the main shaft are cleaned and lubricated. If this is not effective, the narrow gear or shaft must be replaced.

• The shifting mechanism may not be properly adjusted or lubricated, which should be done immediately.

• The Synchromesh unit may be jammed or damaged. Damaged parts must be replaced. If there is no damage, immediately lubricate the unit.

• The ball joint of the shift lever may be binding, which it should.

3. Gears collide when changing:

• The clutch adjustment may be incorrect, which can be checked and corrected if necessary.

• The clutch connection can be constrained, which can be repaired or lubricated as needed.

• Clutch housing misalignment can be another reason, which can be checked on the rear side and corrected if necessary.

• Components of the shifting mechanism or synchronizer assemblies can be worn or damaged. To correct this, the gear must be removed and disassembled. During the inspection, defective components can be identified and replaced.

• The lubricant may be of the wrong specification or its level may be lower. To remedy this, empty and refill the gearbox with suitable oil. Also, check for any source of the leak if the level was low and repair if necessary.

4. Transmission oil leak:

• Damaged oil seals, which should be replaced.

• Seals damaged or even missing. The only alternative is replacement.

• The bolts on the shift cover may be loose, which should be properly tightened.

• The oil used may be more diluted than specified. In this case, the entire oil must be drained and replaced with new oil of suitable characteristics.

• The vent (vent) hole in the top of the gearbox may be blocked, which could open.

• The oil level in the gearbox may be higher than required; excess oil must be drained.

• The drain plug may be loose or damaged, which can be tightened or replaced as needed.

• The gearbox may be cracked. If the cracks do not extend to the bearing seats, the bearing can be welded, otherwise, it must be replaced.