For 1990-2009 cars

Complaint/Condition | Possible Causes | Corrections
--- | --- | ---
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.