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GEAR BOX G-76
TROUBLE SHOOTING
Sr.No.Problem
Possible Cause
Remedy
1.
Hard and / or
Check the synchro cone wear
Change synchro cone and gear.
noisy gear shifting
Insufficient lubricant, improper
Fill to proper lever with
linkage.
grade or quality.
recommended oil. Rectify
leakage, if any.
Defective clutch linkage or gear
Rectify/adjust clutch/gear shift
linkage
Damaged main shaft spigot
Replace damaged parts.
roller baring.
Worn or wrapped gear shift fork /
Repair or replace the damaged
shifter rods etc.
parts.
Shifter sleeve tight on matching
Repair or replace
gears.
2.
Slips out of gear
The soft in the gear shifter rod
Replace the shifter rod.
towards front is shallow.
The pressure spring is weak or
Replace the pressure spring.
broken.
Dog teeth on gears worn out
Replace the affected gears.
Shifter sleeve worn out
Replace the affected sleeve
Shifter fork thrust pad/surface worn.
Replace the damaged parts.
Excess end play in drive, main or
Replace / repair
counter
Gear box mounting loose.
Tighten mounting.
3.
Gears sticky
Insufficient lubricant, improper
Fill the proper lever with
grade or quality.
recommended oil, rectify leakage
if any
Sliding shifter sleeve synchro
Repair / replace.
cone jammed.
4.
Noisy gears
Insufficient lubricant, improper
Rectify leakage if any fill to
grade or quality
proper level with recommended oil
Excess end play in drive, main or
Repair / replace
counter shaft.
Gear box out of line with clutch
Loosen gear box mounting.
housing.
Realign and secure.
5.
Loss of drive
Defective clutch
Rectify / replace
Striped teeth on affected meshing Replace damaged parts.
gears.
6.
Repeated gear failure Breather chocked
Clean and refit breathe.
Insufficient or improper grade or
Fill to proper level with recommended
quality
oil after stopping leakages.
Defective clutch
Adjust or replace clutch.
Improper assembly or installation of Gear box front face must lie flat flush
gear box, Incorrect location of shifter with mating clutch housing face.
sleeve on the main shaft during
Tighten bolts only after the gear is in
assembly.
place.