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
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