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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