HEXA

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.