SAFARI

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59
GEAR BOX G-76
Problem Possible Cause Remedy
27. TROUBLESHOOTING
1. Hard and / or noisy gear shifting
linkage
Check the synchro cone wears
insufficient 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
matching gears.
Change synchro cone and gear.
Fill to proper lever with
recommended oil. Rectify. Rectify/
adjust clutch/gear shift.
Replace damaged parts. Repair or
replace the damaged parts.
2. Slips out of gear The soft in the gear shifter rod
towards front is shallow.
The pressure spring is weak or
broken.
Dog teeth on gears 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 shifter rod.
Replace the pressure spring.
Replace the affected gears.
Replace the affected sleeve
Replace the damaged parts.
Replace / repair or
Tighten mounting.
3. Gears sticky Insufficient lubricant, improper
grade or quality. if any
Sliding shifter sleeve synchro
cone jammed.
Fill the proper lever with
recommended oil, rectify leakage
Repair / replace parts if necessary.
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
housing.
Rectify leakage if any fill to proper
level with recommended oil
Repair / replace
Loosen gear box mounting.
Realign and secure.
5. Loss of drive Defective clutch. Striped teeth on
affected meshing gears.
Rectify / replace
Replace damaged parts.
6. Repeated gear failure Breather chocked. Insufficient or
improper grade or quality Defective
clutch Improper assembly or
installation of Gear box, Incorrect
location of shifter sleeve on the
main shaft during assembly.
Clean and refit breather. Fill to
proper level with recommended
Oil after stopping leakages. Adjust
or replace clutch.
Gear box front face must lie flat
flush
With mating clutch housing face.
Tighten bolts only after the gear is
in place.