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Troubleshooting
1
FSO-2405 2nd Ed. 02/07 General Information
Problem Probable cause Possible solution Reference
Hard shifting Malfunction of Verify and adjust clutch As to vehicle’s
clutch shop manual
Worn or damaged Replace As to vehicle’s
flywheel bushing or instruction manual
bearing
Not recommended Replace Recommended
lubricant lubricant - page 23
Worn or damaged Replace damaged Gear shift housing
gear shift lever parts - page 157
components
Worn or damaged Replace rings Synchronizer
synchronizer rings assemblies -
page 140
Excessively worn Replace synchronizer Synchronizer
or damaged assemblies assemblies -
synchronizer page 140
assemblies
(springs, keys,
sleeve or hub)
Worn or damaged Replace worn or As to this manual
shifting system damaged parts instructions
components (shift
yokes, nylon pads,
bars, shift blocks)
Mainshaft or Adjust end play End play
countershaft end adjustment -
play improperly page 148
Hard gear Malfunction of Verify and adjust As to vehicle’s
disengaging clutch clutch shop manual
Worn or damaged Replace damaged Gear shift housing
gear shift lever parts - page 157
components
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