Chapter 11 Manual Transaxle Problems, Troubleshooting, and Service 229 Copyright by Goodheart-Willcox Co., Inc. Gear Clash Gear clash is a grinding noise that is heard when a gear is first engaged. For this problem, always check the clutch adjustment and condition before working on the transaxle. A clutch that does not fully disengage is the most common cause of gear clash, especially if the clash occurs in every gear. If the clutch checks out all right, or if the clashing occurs only in one gear, check for worn transaxle synchro- nizers. In a few cases, loose mounting bolts or misalignment will cause gear clash. Abnormal Noise An abnormal noise in the manual transaxle is a noise above normal sound level during vehicle operation. Noises that are most noticeable may sound like whining or rum- bling and may change from gear to gear, varying directly with the reduction ratio. Low gear, with its higher gear ratio, for instance, is usually noisier than high gear. Front-wheel drive vehicles normally have higher noise levels than rear-wheel drive vehicles, since the moving parts are mostly concentrated at the front. Be sure to eliminate the engine, clutch, CV axle, and wheel bearings as possible causes of the problem. If the noise occurs in one gear only or in Neutral with the vehicle stopped, you can safely assume that the problem is in one of the gears or synchronizers in the transaxle. If the transaxle is noisy in every gear, including Neutral, first check for a low oil level. Other defects that could cause noise in every gear (and sometimes Neutral) are worn or damaged transaxle transmission gears. Rumbling noises are often caused by worn or damaged bearings on the input or output shafts or in the differential assembly. Noise in every gear when moving may be caused by a defective speedometer gear. A clunking or slapping noise heard when the engine is accelerated or decelerated may be caused by excessive backlash in the moving parts, most commonly in the dif- ferential unit. This can be due to worn or missing thrust washers, badly worn gears, worn or misaligned bearings, or loose bolts. Be sure to check the clutch, engine mounts, and CV axles before removing the transaxle. Clunking noises are much more likely to be coming from the CV axles than the transaxle. Correcting most noises requires transaxle removal to gain access to defective gears or bearings. In some cases, such as with loose bolts or misalignment, the problem can be fixed without removing the transaxle. Warning: Always keep safety uppermost in your mind when checking for transaxle problems. Be cautious around rotating parts when testing the transaxle with the vehicle on a lift. The CV axles and tires rotate at high speeds and can cause severe injury. Always support the lower control arms so the front wheels are at or near their normal position in relation to the vehicle body. Operation of the CV axles at excessive angles by allowing them to hang will cause severe CV joint damage and possible injury to anyone near the vehicle. When testing a front-wheel drive vehicle on the lift, never exceed 30 mph (48 km/h). In-Car Manual Transaxle Service Do not remove the transaxle until you are sure it must be removed. In many cases, the transaxle can be serviced without removing it from the vehicle. For instance, the shift linkage, axle seals, and speedometer gears can be serviced without removing the transaxle. External shift linkage is one area of the manual trans- axle that is vital to proper operation and that can be repaired without transaxle removal. The procedures for adjusting transaxle shift linkage are similar to the procedures for adjusting linkage on rear-wheel drive manual transmis- sions. The linkage of a front-wheel drive vehicle, however, is usually not contained inside the transaxle in the manner of many rear-wheel drive transmissions, since the transaxle is located well ahead of the passenger compartment. Many transaxles use cables to connect the shift mechanism of the gearshift lever assembly to the transaxle gears. Most cable adjustment mechanisms are located at the gearshift lever assembly. Adjustments can be made by removing the console or shift boot to reach the adjustment mechanism. If the vehicle uses a shift rod mechanism, the adjustment must usually be made under the vehicle or at the transaxle under the hood. Manual Transaxle Removal If the transaxle has internal problems, such as defec- tive gears, bearings, or shafts, it will generally have to come out of the vehicle. Note that in some instances, however, certain internal parts can be serviced with the transaxle in the vehicle by removal of a sheet metal or aluminum access cover. Most manual transaxles can be removed from under- neath the vehicle without removing the engine. A few vehi- cles are designed so that the transmission and engine must be removed as a unit. On others, under-the-hood clearances are so close that it is easier to remove them this way. In this case, you must have a good engine hoist and know how to use it. The following general procedures explain how to remove a manual transmission from a vehicle. The removal process presented in this chapter assumes the transaxle can be removed without removing the engine. Keep in mind that the removal process is much different from that used on a rear-wheel drive transmission. Note that you should