Fluid leakage

The fluid level is high.

Drain any excess fluid.

The shift control shaft spring loaded locking pin is leaking.

Remove the pin. Replace with the manual transaxle shift lever hole plug P/N 90105651. Verify the leak is eliminated.

The end cover is loose or the gasket is damaged.

Replace the gasket and tighten to specification. Add florescent dye to verify the leak is eliminated.

The case to clutch housing interface seal is damaged.

Apply sealant and tighten to specification. Add florescent dye to verify the leak is eliminated.

The axle seal is damaged.

Replace the axle seal. Add florescent dye to verify the leak is eliminated.

The input shaft seal is damaged.

Replace the clutch slave cylinder.

The shift control shaft seal is damaged.

Replace the seal. Add florescent dye to verify the leak is eliminated.

The back-up lamp switch is loose.

Remove the switch, inspect the gasket, and replace if necessary. Install the switch and tighten to specification. Verify the leak is eliminated.

Casting porosity

Add florescent dye to verify case leakage exists. Replace the case if necessary.

The reverse idler gear shaft bolt is loose, or the O-ring is damaged.

Remove the bolt, inspect the O-ring, and replace if necessary. Tighten the bolt to specification.

The reverse idler gear shaft bracket bolt is loose.

Tighten the bolt to specification. Verify the leak is eliminated.

Transaxle hops out of gear

There is operator error/incomplete shift travel.

Demonstrate the correct shifting.

The shift forks are worn.

Replace the shift fork.

The control shaft lever assembly is worn or damaged.

Replace the control shaft lever assembly.

The control assembly rod is out of adjustment.

Adjust the control assembly rod. Refer to "Shift Linkage Adjustment" in this service manual.

The control assembly is broken.

Replace the control assembly.

The manual transaxle internal shift mechanism malfunctions.

Disassemble the transaxle and repair as necessary.

Grinds during shifting or gear clashing

The blocking ring/gear is worn or burnt.

Replace the components. Check the clutch pedal travel.

The shift forks are worn.

Replace the shift fork.

The clutch is worn or damaged.

Inspect the clutch disc and replace if necessary.

Follow the "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary.

Transaxle gear rattle in neutral

The clutch disc damper fails.

Replace the clutch disc.

The engine idle speed is low.

Correct the condition causing low idle speed.

Difficult to shift/block out (static/engine OFF)

The control assembly rod is out of adjustment.

Adjust the control assembly rod. Refer to "Shift Linkage Adjustment" in this service manual.

The manual transaxle internal shift mechanism malfunctions.

Disassemble the transaxle and repair as necessary.

The control shaft lever assembly is broken.

Replace the control shaft lever assembly.

The control assembly is damaged.

Replace the control assembly.

Difficult to shift/block out (dynamic/engine running)

The clutch is worn or damaged.

Inspect the clutch disc and replace if necessary.

Follow the "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary.

The synchronizer/gear is worn.

Replace the components.

The shift fork is worn.

Replace the shift fork assembly.

The driven bushings (output shaft) is worn.

Replace the components.

The drive gear needle bearings (input shaft) are worn.

Replace the components.

The clutch is not releasing.

Verify clutch pedal travel and replace the clutch if necessary.

Difficult to shift/block out (general)

The shift fork is worn.

Replace the shift fork.

The control assembly rod is out of adjustment.

Adjust the control assembly rod. Refer to "Shift Linkage Adjustment" in this service manual.

The synchronizer sleeve tooth point is damaged.

Replace the synchronizer assembly.

The clutch is worn or damaged.

Inspect the clutch disc and replace if necessary.

Follow the "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary.

The clutch is not releasing.

Verify the clutch pedal travel and replace the clutch if necessary.

Difficult to select gates

The control shaft lever assembly is broken.

Replace the control shaft lever assembly.

The shifter assembly is damaged.

Replace the shifter assembly.

Stuck in gear

The control shaft lever assembly is broken.

Replace the control shaft lever assembly.

The manual transaxle internal shift mechanism malfunctions.

Disassemble the transaxle and repair as necessary.

The shift fork is damaged.

Replace the shift fork assembly.

Vehicle does not move (stuck in 2 gears)

The manual transaxle internal shift mechanism malfunctions.

Disassemble the transaxle and repair as necessary.

Noisy shifting

The shifter assembly is damaged.

Inspect the shifter assembly and replace if necessary.

Noisy in neutral with the engine ON

The input shaft roller bearings are worn.

Inspect the roller bearings and replace if necessary.

The driven gear bushings (output shaft) are worn.

Inspect the components and replace if necessary.

The clutch slave cylinder are worn.

Inspect the release bearing and replace if necessary.

Noisy around turns

The differential gear is worn or damaged.

Inspect the differential gear and replace if necessary.

Noisy in all gears

The fluid level is low.

Add manual transaxle lubricant.

The drive gear needle bearings (input shaft) are worn.

Inspect the components and replace if necessary.

The driven gear bushings (output shaft) are worn.

Inspect the components and replace if necessary.

First, second, third, fourth, or fifth gears are chipped, scored, or worn.

Inspect the components and replace if necessary.

Noisy in first only

First gears are chipped, scored, or worn.

Inspect the first gears and replace if necessary.

The 1-2 synchronizer is damaged or worn.

Inspect the synchronizer and replace if necessary.

Noisy in second only

Second gears are chipped, scored, or worn.

Inspect the second gears and replace if necessary.

The 1-2 synchronizer is damaged or worn.

Inspect the synchronizer and replace if necessary.

Noisy in third only

Third gears are chipped, scored, or worn.

Inspect the third gears and replace if necessary.

The 3-4 synchronizer is damaged or worn.

Inspect the synchronizer and replace if necessary.

Noisy in fourth only

Fourth gears are chipped, scored, or worn.

Inspect the fourth gears and replace if necessary.

The 3-4 synchronizer is damaged or worn.

Inspect the synchronizer and replace if necessary.

Noisy in fifth only

Fifth gears are chipped, scored, or worn.

Inspect the fifth gears and replace if necessary.

The fifth synchronizer is damaged or worn.

Inspect the synchronizer and replace if necessary.

Noisy in reverse only

The reverse idler gear or idler bushing is worn or damaged.

Inspect the idler gear and bushing and replace if necessary.

The 1-2 synchronizer sleeve is damaged or worn.

Inspect the synchronizer and replace if necessary.