TCM FD35C9 - 4.1 Clutch Troubleshooting; 4.2 Drive Unit (Synchromesh Type) Troubleshooting

4-1
4.1 CLUTCH
Problem Probable cause Remedy
1. Slipping clutch
Clutch pedal dose not have play Adjust pedal.
Pressure spring deteriorated or damaged Replace.
Pressure plate unevenly worn Correct or replace.
Facing worn, hardened or contaminated with lubricant Clean or replace.
Flywheel facing contact surface worn Correct or replace.
2. Clutch drags
Too large clutch pedal play Adjust pedal.
Warped clutch disc Replace.
Corroded splines of clutch disc and main drive shaft Correct.
Clutch yoke end worn Replace.
Release cylinder malfunctioning or oil leakage Correct or replace.
Clutch booster malfunctioning Correct or replace.
3. Clutch noisy
while operated
Facing hardened or worn Replace.
Rivet heads interfering Replace.
Clutch disc torsion spring deteriorated or damaged Replace.
Clutch disc cushioning plate deteriorated or damaged Replace.
Pressure spring deteriorated or damaged Replace.
4. Thrust bearing
noisy
Thrust bearing worn, seized or damaged Replace.
Retainer worn or damaged Replace.
Support worn or damaged Replace.
Clutch yoke end worn Replace.
4.2 DRIVE UNIT (SYNCHROMESH TYPE)
Problem Probable cause Remedy
1. Transmission
noisy
Low lubricant level Add oil.
Gears worn or damaged Replace part.
Bearings worn or damaged Replace part.
2. Hard shifting into
gear
Shift arm deformed or worn Correct or replace.
Worn shift arm groove in sleeve Replace part.
Block ring and synchronizing cone seized
Replace gear assembly and
block ring with new ones.
Clutch drags Check and adjust.
Sleeve spline chamfer ends or dog tooth chamfer ends are
worn or damaged
Replace gear assembly and
sleeve with new ones.
Block ring cone friction surface worn Replace block ring.
3. Gears disengage
Shift arm deformed or worn Correct or replace.
Worn notch groove in shift rod Replace part.
Shift arm ball worn or spring deteriorated Replace part.
4. Differential noisy
Gears worn or damaged Replace part.
Improper backlash of bevel gear Adjust.
Bearing worn or damaged Replace part.
Low lubricant level Add oil.
5. Defective
operation of
differential
Gear teeth worn or damaged Replace part.
Drive shaft damaged Replace part.