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, 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. Fill to proper level with recommended oil. Rectify/adjust clutch/gear shift. Repair or replace damaged parts. Replace damaged parts. 2 Slips out gear The pressure spring is weak or broken. 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 recommended oil. Rectify leakage. Replace / repair 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 with recommended oil. 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 choked. Insufficient or improper grade or quality 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 recommended 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.
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