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Modern Automotive Modern Automotive TechnologyTechnology Chapter 56Chapter 56
Manual TransmissionManual TransmissionDiagnosis & RepairDiagnosis & Repair
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Learning ObjectivesLearning ObjectivesDiagnose common manual transmission problems.Remove a standard transmission from a vehicle.Disassemble and inspect a manual transmission.Assemble a manual transmission.Install a manual transmission.Adjust manual transmission linkage.Cite and observe safety rules for transmission service.
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Common Transmission Common Transmission ProblemsProblems
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Manual TransmissionManual Transmission Diagnosis & RepairDiagnosis & Repair
1. When using a transmission jack, it is necessary to get help from another mechanic to lift the transmission.
2. When replacing a gear on the output shaft, you do not have to replace the matching gear set on the input shaft.
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Transmission RemovalTransmission Removal
Use a hoist and transmission jack
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Transmission DisassemblyTransmission Disassembly
Using a dummy shaft, drive out the countershaft
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Transmission DisassemblyTransmission Disassembly
Remove the input and output shaft assemblies
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3. A grinding sound or gear clashing noise when shifting is frequently caused by incorrect transmission linkage adjustment.
4. When a transmission jumps out of gear, the driver’s shift lever does not “pop” into reverse while driving.
Manual TransmissionManual Transmission Diagnosis & RepairDiagnosis & Repair
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Inspect SynchronizersInspect Synchronizers
Check shift forks and synchronizers for wear
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Inspect SynchronizersInspect Synchronizers
Ridges must be sharp–if worn, gear clash may occur
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Measuring Measuring Synchronizer Ring Synchronizer Ring
ClearanceClearance
Blocking ring wear reduces clearance
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Inspect and Assemble Shift Inspect and Assemble Shift MechanismMechanism
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Linkage AdjustmentLinkage Adjustment
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5. Lubricant leaks in a manual transmission are caused by ruptured gaskets, worn seals, loose fasteners, or damage to the case, housings, or covers.
6. When removing a transmission, use a transmission jack stand because it allows you to stand while working.
Manual TransmissionManual Transmission Diagnosis & RepairDiagnosis & Repair
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Removing the Oil SealRemoving the Oil Seal
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Installing a New SealInstalling a New Seal
Coat the outside of the seal with nonhardening sealer before installing
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7. When a manual transmission is noisy, check fluid (lubrication level) not the the transmission bearings first.
8. If there is noise in only one gear of a transmission, then the problem is probably due to components related to that gear.
Manual TransmissionManual Transmission Diagnosis & RepairDiagnosis & Repair
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Removing a BearingRemoving a Bearing
A special puller may be needed
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Installing a New BearingInstalling a New Bearing
Use a driver to install new bearings
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9. The wobbling action of the shaft due to worn shift bearings or bushing will make a new seal leak.
10. If there is noise in all gears of a transmission, something common to all of the gears is at fault.
Manual TransmissionManual Transmission Diagnosis & RepairDiagnosis & Repair
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Transmission DisassemblyTransmission Disassembly
Remove the rear extension housing
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Checking RunChecking Run--outout
Check runout if gear wear is uneven. Dial indicator movement equals runout
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Learning ObjectivesLearning ObjectivesDiagnose common manual transmission problems.Remove a standard transmission from a vehicle.Disassemble and inspect a manual transmission.Assemble a manual transmission.Install a manual transmission.Adjust manual transmission linkage.Cite and observe safety rules for transmission service.