SAFARI

59 GEAR BOX G-76 Sr.No. 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. Fi l l to proper lever wi th 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. Fi l l the proper lever wi th 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 wi th recommended oi l 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.