GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Cobalt 🢒 Transmission/Transaxle 🢒 Manual Transmission - Getrag 5 Speed 🢒 Transmission Gear Clash When Shifting Gears

Diagnostic Aids

Gear clashing may be caused by shifting at too high of an engine RPM or by rushing the shift. If gear clashing is occurring in more than one gear, the clutch may not be releasing properly for proper synchronizer operation.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

  1. This step tests for the proper releasing of the clutch. If the clutch reserve is not proper, the mainshaft gears may still be turning causing the gear clashing.

    2.

  2. This step inspects for the proper transaxle fluid. A special fluid is required for the correct lubrication of the synchronizers.

    3.

  3. A static shift test is performed by shifting into all of the gear positions with the engine not operating. While performing the test, you should note how the shift lever movement is felt. Also, while shifting from one gear to another, feel for binding in the shift rails. You should be able to feel the detent plungers operating when coming out of a gear and going into a gear. Excessive play in the gear shift lever may prevent the shift forks from fully engaging the synchronizer.

    4.

  4. A dynamic shift test is performed by shifting into all of the gear positions with the engine operating. Test for the correct mesh of the synchronizers, and for the clutch releasing correctly. Move the shift lever and feel for the synchronizer sleeve to just release from the gear, then let up on the clutch pedal. Depress the clutch pedal and move the shift lever to engage that gear again. If it shifts back into the gear without clashing, the clutch is releasing correctly and the synchronizer is working. If clashing occurs, test on another gear. If all gears clash, the clutch is not releasing correctly.

Step

Action

Yes

No

DEFINITION: Noise from the transaxle when shifting gears. A grinding or grating sound, when the synchronizer sleeve is engaging with the selector teeth on the speed gear. A suspected internal transaxle condition, if the noise only occurs in one gear.

1

Did you review the Symptoms - Manual Transmission and perform the necessary inspections?

Go to Step 2

Go to Symptoms - Manual Transmission

2

With the engine operating, does the transaxle shift from neutral to any gear, without the vehicle lurching or gear clashing?

Go to Step 5

Go to Step 3

3

Inspect for proper clutch operation. Refer to Clutch System Description and Operation.

Does the clutch operate properly?

Go to Step 5

Go to Step 4

4

Repair the clutch system. Refer to Symptoms - Clutch.

Did you find and repair the condition?

Go to Step 11

Go to Step 5

5

Inspect for the correct transaxle fluid level and the proper fluid. Refer to Transmission Fluid Check .

Is the transaxle fluid level correct and at the proper level?

Go to Step 7

Go to Step 6

6

Fill the transaxle to the correct level, or change the transaxle fluid if it is not the correct type.

Does the transaxle still have gear clash?

Go to Step 7

Go to Step 11

7

  1. Perform a static shift test on the transaxle.
  2. Test for the following:
    3. • Blockage preventing full shift lever movement
    • Excessive movement in the shift lever
    • Binding in the shift lever
    • Detent plungers or shift rails binding
    • Shift cable binding
    • Shift cable proper adjustment

Did the transaxle shift smoothly into the gear that is clashing?

Go to Step 10

Go to Step 8

8

Remove the floor console. Refer to Front Floor Console Replacement.

Inspect for the following:

    • Loose mounting
    • Foreign debris

Did you find and repair the condition?

Go to Step 12

Go to Step 10

9

Inspect for proper shift cable adjustment. Refer to Shift Cable Adjustment .

Did you find and repair the condition?

Go to Step 12

Go to Step 10

10

  1. Perform a dynamic shift test on the transaxle.
  2. Test for the following:
    3. • Detent plungers or shift rails binding
    • Synchronizer sleeve binding
    • Gear clashing in more than the suspected gear

Is the transaxle hard to shift into all gears?

Go to Transmission Shifts Hard

Go to Step 11

11
  1. Disassemble the transaxle. Refer to Transmission Case Disassemble.
  2. Inspect the following transaxle components for the gear that is clashing:
    3. • Excessive synchronizer blocking ring to gear clearance
    • Synchronizer sleeve to hub clearance excessive
    • Excessive axial clearance in the speed gear
    • Mainshaft to speed gear bearing or journal worn
    • Shift fork worn or damaged
    • Internal shift control worn or damaged
    • Mainshaft bearing worn or damaged
    • Input gear bearing or pilot bearing worn

Did you find and repair the condition?

Go to Step 12

Go to Diagnostic Aids

12

Operate the system and verify the repair.

Did you correct the condition?

System OK

Go to Step 1