40
Troubleshooting
1
General Information 2nd Ed. 02/07 FSO-2405
Problem Probable cause Possible solution Reference
Hard gear Excessively worn Replace synchronizer Synchronizer
disengaging or damaged assemblies assemblies -
(continuation) 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
adjusted
Gear shift rubbing Malfunction of Verify and adjust As to vehicle’s
clutch clutch shop manual
Malfunction of Verify and adjust As to vehicle’s
clutch linkage linkage shop manual
Worn or damaged Replace As to vehicle’s
flywheel bushing instruction manual
or bearing
Worn or damaged Replace rings Synchronizer
synchronizer rings assemblies -
page 140
Shift yoke nylon Replace Shift bars -
pads worn page 124
Transmission Gear shift lever Adjust console As to vehicle’s
slips out of gear console out of shop manual
position, forcing
the lever
Worn or damaged Replace synchronizer Synchronizer
synchronizer assemblies assemblies -
assemblies page 140
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