SAFARI STORME MY14

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