779 / 1906
GEAR BOX 6450
11
1.4
GENERAL SYMPTOMS DIAGNOSIS:
SR.
NO.
PROBLEM
POSSIBLE CAUSE
REMEDY
1
Hard and Noisy
gear shifting
linkage.
Worn Out synchrocone.
Insufficient lubricant and improper
grade or quality of lubricant.
Leakage if any.
Defective clutch linkage or gear box
linkage.
Damaged main shaft spigot roller
bearing.
Worn or distorted gear shift
fork/shifter rods etc. shifter sleeve
tight on matching gears.
Change synchro cones.
Top up with recommended oil.
Rectify the leakage.
Rectify / adjust clutch /
gearbox linkage.
Repair or replace parts.
Replace damaged parts.
2
Slips out gear
Weak or broken Pressure spring .
Worn out dog teeth on gear.
Worn out Shifter sleeve.
Worn out Shifter fork thrust
pad/surface.
Excess end play in drive shaft, main
shaft or counter shaft.
Loose gear box mounting.
Replace the pressure spring.
Replace the affected gears.
Replace the affected sleeve.
Replace the damaged parts.
Replace the damaged parts.
Replace / repair or tighten the
mounting.
3
Gear sticky
Insufficient lubricant and improper
grade or quality of lubricant.
Jammed sliding of shifter sleeve
synchro conic sleeve.
Top up with recommended oil.
Replace / repair parts if
necessary.
4
Noisy gears
Insufficient lubricant and improper
grade or quality of lubricant.
Excess end play in drive shaft, main
shaft or counter shaft.
Gearbox and clutch housing are not
aligned.
Top up with recommended oil.
Repair or replace damaged
parts.
Properly align the clutch
housing on the dowel and rest
clutch housing properly on
gearbox face.
5
Loss of drive
Defective clutch.
Striped teeth on affected meshing
gears.
Rectify / replace.
Replace damaged parts.
6
Repeated gear
failure
Breather choked.
Insufficient lubricant and improper
grade or quality of lubricant.
Defective clutch.
Improper assembly or installation of
gearbox and incorrect location of
shifter sleeve on the main shaft
during assembly.
Clean and refit breather.
Top up with recommended oil.
Adjust or replace clutch.
Rectify / replace corresponding
assembly parts