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GEAR BOX
10
4.2.1.4 GENERAL SYMPTOMS DIAGNOSIS
SR.
NO.
PROBLEM
POSSIBLE CAUSE
REMEDY
1
Hard and Noisy
gear shifting.
•
Check the synchro cone wear, insuffi-
cient lubricant, improper grade or
quality, leakage if any defective clutch
linkage or gear linkage.
•
Damaged main shaft spigot roller
bearing.
•
Worn or wrapped gear shift fork/shifter
rods etc. shifter sleeve tight on match-
ing gears.
•
Change synchro cone and gear.
Fill to proper level with recom-
mended oil. Rectify/adjust
clutch/gear shift.
•
Repair or replace damaged
parts.
•
Replace damaged parts.
2
Slips out gear
•
The pressure spring is weak or bro-
ken.
•
Dog teeth on gear worn out.
•
Shifter sleeve worn out.
•
Shifter fork thrust pad/surface worn.
•
Excess end play in drive, main or
counter shaft. Gear box mounting
loose.
•
Replace the pressure spring.
•
Replace the affected gears.
•
Replace the affected sleeve.
•
Replace the damaged parts.
•
Replace / repair or tighten
mounting.
3
Gear sticky
•
Insufficient lubricant, improper grade
or quality.
•
If any sliding shifter sleeve synchro
cone jammed.
•
Fill the proper level with rec-
ommended oil. Rectify leakage.
•
Replace / repair parts if neces-
sary.
4
Noisy gears
•
Insufficient lubricant, improper grade
or quality. Excess end play in drive,
main or counter shaft.
•
Gear box out of line with clutch hous-
ing.
•
Rectify leakage if any; fill to
proper level with recommended
oil. Repair / replace.
•
Loosen gear box mounting rea-
lign and secure.
5
Loss of drive
•
Defective clutch.
•
Striped teeth on affected meshing
gears.
•
Rectify / replace.
•
Replace damaged parts.
6
Repeated gear
failure
•
Breather choked.
•
Insufficient or improper grade or quali-
ty of oil.
•
Defective clutch.
•
Improper assembly or installation of
gear box and incorrect location of
shifter sleeve on the main shaft during
assembly.
•
Clean and refit breather.
•
Fill to proper level with recom-
mended oil after stopping
leakages.
•
Adjust or replace clutch.
•
Gear box front face must lie flat
flush with mating clutch housing
face and tighten bolts only after
the gear is in place.