715 / 1906
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.