Manual Transmission

Diagnosis and Repair

Chapter 72

2012 Delmar, Cengage Learning

 Objectives
Diagnose transmission-related problems
Remove a transmission safely in a professional
manner
Disassemble transmissions correctly
Use presses and pullers competently to
disassemble and reassemble transmissions
Diagnose and service synchronizers
Reassemble and install a transmission in a
vehicle

2012 Delmar, Cengage Learning

 Introduction
Important considerations in transmission repair
Proper press and puller use
Locating service information
Disassembling transmissions
Requires controlled force
Each transmission has its own peculiarities
Synchronizers are mostly of the same design

2012 Delmar, Cengage Learning

 Transmission Diagnosis
Clutch problem
Transmission doesn't go into gear
Transmission failure
Results from abuse or misapplication
Determine cause before removal
Some typical symptoms:
Gear clashing during shifting
Hard shifting and jumping out of gear
Unusual noise

2012 Delmar, Cengage Learning

 Lubricant Checks
Lubricant level
Checked by removing the fill plug and inserting
your little finger inside the hole
Check for leaks
Front and rear seals
Any switches
Plug or vents
Gaskets
Oil leakage can result in transmission failure

2012 Delmar, Cengage Learning

 Transmission Removal
Major steps
Removing a transmission can be dangerous
Drain gear oil before installing jack
May be necessary to remove exhaust pipes
Disconnect battery
Remove speedometer cable
Disconnect external shift linkage
Remove and clean transmission
Identify transmission before ordering parts

2012 Delmar, Cengage Learning

 Transmission Disassembly
Major steps
Check service manual before disassembling
Look for damage
Gears develop normal wear pattern with use
Remove front bearing retainer and snap rings
Remove countershaft and mainshaft
Mainshaft removed from rear or top of
transmission
Remove the input shaft
Be careful not to damage gears

2012 Delmar, Cengage Learning

 Disassemble the Mainshaft
Assembly
Major steps
Lay parts out as they are disassembled
Keep parts in order
High-gear synchro clutch hub
Held on mainshaft with a snap ring
Remove snap ring with snap ring pliers
Press or puller pulls synchronizer clutch hub

2012 Delmar, Cengage Learning

 Synchronizer Service
Synchronizer will be
reused
Scribe line on
outside to
reassemble in
same position
Some are marked
from factory
Look for wear
Gears and shift
sleeves
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 Synchronizer Inspection
Best way to tell if synchro is not working
Test-drive the vehicle
Worn synchro
Causes gear clashing
Inspect synchronized gears
Rarely experience excessive wear
Inspect synchro sleeve
Even width across length

2012 Delmar, Cengage Learning

 2012 Delmar, Cengage Learning
 Inspect Blocker Rings
Inspect brass blocker
rings if they are to be
reused
Inside surface should
have sharp edges
Push blocker ring
against polished
tapered surface on
gear that it rides on
Should grab against
chrome surface
2012 Delmar, Cengage Learning
 Inspect Input Shaft and
Mainshaft
Inspect mainshaft splines
May be twisted from abusive driving
Twisted spline prevents drive shaft slip yoke from
sliding in and out of transmission
Inspect drive gear for VSS or speedometer
Located on the output shaft
Rarely suffers damage
A special puller is available to pull these gears

2012 Delmar, Cengage Learning

 Replace Worn Bearings
Use a press and support inside of bearing with
bearing separator
Reassembling: apply pressure on inside of
bearing only

2012 Delmar, Cengage Learning

 Reassemble the Transmission
Before assembling
Locate and assemble any new replacement parts
Two gears operating in mesh
Create wear pattern
Gear is replaced
Corresponding gear also replaced
Using an old gear with a new gear can result in
unacceptable gear noise

2012 Delmar, Cengage Learning

Reassemble the Synchronizers
Reassemble
synchronizer hub
parts
Three inserts are
held in place with
a round spring
Install springs so
they rotate in
opposite directions

2012 Delmar, Cengage Learning

 Reassemble the Mainshaft
Major steps
Install gears
Lubricate parts
liberally
Install synchro hub
Check end play of
assembled parts

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 End Play
Thrust washers
Control end clearance
Determine where gear
will be positioned
Check gear clearance
after all gears are
assembled
Adjust clearance by
changing thickness of
snap ring

2012 Delmar, Cengage Learning

 Needle Bearing Installation
Needle bearings are
sometimes caged
Can also be loose
and installed one at a
time
Count needle
bearings during
disassembly
Service manual
Specifies number of
needle bearings
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 Install New Gaskets
Purchase a new transmission gasket set
Gaskets are not reusable
Gasket working fine previously could leak after
reassembly
Replacing this gasket would be a complicated
repair
Would be done at no charge to the customer

2012 Delmar, Cengage Learning

 Complete the Transmission
Reassembly
Install shift mechanism
Replace extension housing bushing and seal
Use a seal installer to replace the seal without
distorting it

2012 Delmar, Cengage Learning

 Install the Transmission
Major steps
Be sure clutch fork is properly seated on its pivot
Align transmission with engine
Shake transmission while rotating it back and
forth
Install bolts in transmission
Torque to specifications

2012 Delmar, Cengage Learning

 Add Lubricant
Important considerations
Add recommended lubricant before driving the
vehicle
Lubricant level should come to bottom of fill hole

2012 Delmar, Cengage Learning

 Test Drive
Important considerations
Be sure shifts are smooth in all gears
Neutral gate should be accurately aligned
Check outside of transmission for leaks after
returning to shop

2012 Delmar, Cengage Learning