Fluid Leakage

Fluid level high

Drain excess fluid.

Shift housing loose or gasket damaged

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

End cover loose or gasket damaged

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

Case to clutch housing interface seal damaged

Reapply sealant and torque to specification. Add florescent dye to verify leak is eliminated.

Axle seal damaged

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

Input shaft seal damaged

Replace seal and bearing assembly. Add florescent dye to verify leak is eliminated.

Shift housing seal damaged

Replace shift housing assembly. Add florescent dye to verify leak is eliminated.

Speed sensor loose or O-ring damaged

Replace O-ring if necessary. Torque to specification. Add florescent dye to verify leak is eliminated.

Back-up lamp switch loose

Torque to specification. Add florescent dye to verify leak is eliminated.

Casting porosity

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

Transaxle Hops-Out of Gear

Operator error/incomplete shift travel

Demonstrate correct shifting.

Worn/missing fork inserts/bushings

Replace shift fork assembly.

Shift cable clip/retainer off

Install a new clip/retainer.

Shift cable damaged/bent

Replace shift cable assembly.

Shifter assembly broken

Replace shifter assembly.

Damaged/binding shift housing components

Replace shift housing assembly.

Worn synchronizer spline lock

Replace synchronizer assembly.

Grinds During Shifting or Gear Clashing

Worn/burnt blocker ring/gear

Replace components. Check release bearing travel.

Worn/missing fork inserts/bushings

Replace shift fork assembly.

Worn/bent shift forks

Replace shift fork assembly.

Clutch worn or damaged

Replace clutch disc.

Transaxle Gear Rattle in Neutral

Clutch disc damper failure

Replace clutch disc.

Engine idle speed low

Set to correct idle speed.

Difficult to Shift/Blockout Static Engine Off

Shift cable clip/retainer off

Replace the clip/retainer.

Shift cable damaged/bent

Replace shift cable assembly.

Damaged/binding shift housing components

Replace shift housing assembly.

Shifter assembly damaged

Replace shifter assembly.

Difficult to Shift/Blockout Dynamic Engine Running

Clutch worn or damaged

Replace the clutch disc.

Worn synchronizer/gear

Replace the components.

Worn/missing fork inserts/bushings

Replace the shift fork assembly.

Worn/bent shift forks

Replace the shift fork assembly.

Worn/burnt blocker ring/gear

Replace the components.

Worn Driven gear needle bearings output shaft

Replace the components.

Worn drive gear needle bearings input shaft

Replace the components.

Clutch not releasing

Replace the clutch and verify the release bearing travel.

Difficult to Shift Blockout General

Worn/missing fork inserts/bushings

Replace the shift fork assembly.

Shift cable damaged/bent

Replace the shift cable assembly.

Worn/bent shift forks

Replace the shift fork assembly.

Synchronizer sleeve tooth point damaged

Replace the synchronizer assembly.

Clutch worn or damaged

Replace the clutch disc.

Clutch not releasing

Replace the clutch and verify the release bearing travel.

Difficult to Select Gates

Cable guide detached/missing

Install a new guide.

Select cable clip/retainer off

Install a new clip/retainer.

Damaged shift housing (select pivot)

Replace the shifter assembly.

Shifter assembly damaged

Replace the shift housing assembly.

Stuck in Gear

Shift cable clip/retainer off

Install a new clip/retainer.

5th/Rev actuator/fork clip missing or misinstalled

Install a new clip.

Damaged shift housing

Replace the shift housing assembly.

Damaged shift fork

Replace the shift fork assembly.

Vehicle Does Not Move (Stuck in two gears)

5th/Rev actuator/fork clip missing or misinstalled

Install a new clip.

Damaged shift fork

Replace the shift fork assembly.

Damaged shift housing

Replace the shift housing assembly.

Noisy Shifting

Shifter cable/clip retainer missing

Install a clip/retainer.

Shifter assembly damaged

Inspect the shifter assembly and replace if necessary.

Noisy in Neutral with Engine On

Quill bearing worn or damaged

Inspect the quill bearing and replace if necessary.

Worn input shaft ball bearings

Inspect the ball bearings and replace if necessary.

Worn driven gear needle bearings (Output shaft)

Inspect the components and replace if necessary.

Worn clutch release bearing

Inspect the release bearing and replace if necessary.

Noisy Around Turns

Differential gear wear/damage

Inspect differential gear and replace if necessary.

Noisy in All Gears

Fluid level low

Add transaxle fluid.

Worn drive gear needle bearings (input shaft)

Inspect components and replace if necessary.

Worn driven gear needle bearings (output shaft)

Inspect components and replace if necessary.

Chipped, scored, or worn; 1st, 2nd, 3rd, 4th, or 5th gears

Inspect components and replace if necessary.

Noisy in First Only

Chipped, scored, or worn 1st gears

Inspect 1st gears and replace if necessary.

Damaged or worn 1-2 synchronizer

Inspect synchronizer and replace if necessary.

Noisy in Second Only

Chipped, scored, or worn 2nd gears

Inspect 2nd gears and replace if necessary.

Damaged or worn 1-2 synchronizer

Inspect synchronizer and replace if necessary.

Bent reverse lever

Replace reverse shift lever assembly.

Noisy in Third Only

Chipped, scored, or worn 3rd gears

Inspect 3rd gears and replace if necessary.

Damaged or worn 3-4 synchronizer

Inspect synchronizer and replace if necessary.

Noisy in Fourth Only

Chipped, scored, or worn 4th gears

Inspect 4th gears and replace if necessary.

Damaged or worn 3-4 synchronizer

Inspect synchronizer and replace if necessary.

Noisy in Fifth Only

Chipped, scored, or worn 5th gears

Inspect 5th gears and replace if necessary.

Damaged or worn 5th synchronizer

Inspect synchronizer and replace if necessary.

Noisy in Reverse Only

Worn or damaged reverse idler gear or idler bushing

Inspect idler gear and bushing and replace if necessary.

Damaged or worn 1-2 synchronizer sleeve

Inspect synchronizer and replace if necessary.

Bent reverse lever

Replace reverse shift levers assembly.

Clutch Does Not Release

Pedal travel short. Object interferes with pedal

Move the object.

Hydraulic system failure

Refer to Clutch Hydraulic System Diagnosis . Replace if necessary.

Clutch disc hub binding

Clean the hub and shaft, lightly grease the shaft with high-temp grease P/N 21005995 or equivalent, and replace if necessary.

Clutch disc warped or bent

Replace the clutch disc.

Pressure plate to flywheel bolts loose

Torque the bolts to specification and verify operation.

Pressure plate faulty or damaged

Inspect the pressure plate and replace if necessary.

Fork and bearing not assembled correctly

Install properly.

Input shaft splines worn or damaged

Inspect the input shaft, and replace if necessary.

No Pressure or Very Little Resistance in Clutch Pedal

Hydraulic system failure

Refer to Clutch Hydraulic System Diagnosis and replace if necessary.

Clutch feels "Spongy" When Depressed

Hydraulic system failure

Refer to Clutch Hydraulic System Diagnosis and replace if necessary.

Pedal Effort High for Entire Pedal Travel

Hydraulic system failure

Refer to Clutch Hydraulic System Diagnosis and replace if necessary.

Clutch facing worn

Replace the clutch disc.

Release bearing binding

Inspect the release bearing, and replace if necessary.

Pressure plate damaged or faulty

Inspect the pressure plate, and replace if necessary.

Pedal bushings dry or worn

Clean or replace the bushing and lubricate with lithium grease.

High Clutch Engage Point

Clutch facing worn

Replace the clutch disc.

Clutch is Slipping

Oil soaked clutch facing

Identify/seal the source of the oil leak. and replace the clutch disc.

Clutch facing is torn or worn.

Replace the clutch disc.

Clutch facing burnt or glazed

Torque the bolts to specification and inspect the clutch disc. Replace if necessary.

Pressure plate to flywheel bolts loose

Inspect the components and replace if necessary.

Pressure plate or flywheel faulty, or damaged

Adjust the switch, inspect the clutch disc for excessive wear and replace if necessary.

Cruise switch misadjusted

Refer to Clutch Hydraulic System Diagnosis and replace if necessary.

Hydraulic system failure

Refer to "Clutch Housing Cover Adjustment" and replace if necessary.

Clutch housing cover not adjusted properly

Refer to "Clutch Housing Cover Adjustment" and replace if necessary.

Mismatch of clutch and clutch housing cover

Inspect the part number labeled on the clutch.

Clutch is Grabbing, Chattering, or Shuddering

Mount misadjusted/loose

Torque the bolts to specification and inspect.

Clutch disc warped or bent

Replace the clutch disc.

Clutch disc damper failure

Replace the clutch disc.

Pressure plate or flywheel warped, faulty , or damaged

Inspect the components and replace if necessary.

Clutch disc hub binding

Clean the hub and shaft, lightly grease the shaft with high-temp grease P/N 21005995 or equivalent, and replace if necessary.

Light oil or grease on clutch facing

Identify/seal the source of the leak, and replace the clutch disc.

Clutch facing burnt or glazed

Replace the clutch disc.

Pressure plate to flywheel bolts loose

Torque the bolts to specification and inspect the clutch disc, and replace if necessary.

Input shaft splines worn or damaged

Inspect the input shaft, and replace if necessary.

Release bearing binding

Inspect the release bearing, and replace if necessary.

Clutch is Noisy When Disengaging

Release bearing faulty

Inspect the release bearing, and replace if necessary.

Pedal bushing worn or dry

Clean or replace and lubricate with lithium grease.

No grease on ball stud

Clean, lubricate with high-temp grease P/N 21005995 or equivalent, and inspect.

Clutch fork stabilizer missing

Replace the stabilizer and inspect.

Clutch neutral switch click

Add foam pad to the pedal.

Clutch is Noisy When Engaging

Release bearing faulty

Inspect the release bearing, and replace if necessary.

Pedal bushing worn or dry

Clean or replace and lubricate with lithium grease.

No grease on ball stud

Clean, lubricate with high-temp grease P/N 21005995 or equivalent, and inspect.

Clutch fork stabilizer missing

Replace the stabilizer and inspect.

Clutch neutral switch click

Add foam pad to pedal.

Clutch Pedal is Squeaking

Pedal bushing worn or dry

Clean or replace the bushings and lubricate with lithium grease.

Hydraulic system failure

Refer to Clutch Hydraulic System Diagnosis and replace if necessary.

Clutch Pedal is Buzzing/Growling

Hydraulic system failure

Refer to Clutch Hydraulic System Diagnosis and replace if necessary.

Pressure plate to flywheel bolts loose

Torque the bolts to specification and inspect the clutch disc, replace if necessary.

Clutch fork stabilizer missing

Replace the stabilizer and inspect.