SAFARI

56 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.