Chapter 11 Manual Transaxle Problems, Troubleshooting, and Service 239 Copyright by Goodheart-Willcox Co., Inc. 4. Install the starter, if it was removed, and the dust cover. Install the speedometer cable assembly, and install the exhaust pipes, if they were removed. 5. Install the CV axles, making sure to match up the alignment marks made during removal. If the CV axles are held in the transaxle with retaining clips, replace the clips with new ones to ensure the axle does not pop out when the vehicle suspension moves. Do not stretch the clips in the attempt to ensure that they hold, since this will make the CV axle difficult to remove the next time it needs service. 6. Install any other frame and body parts that were removed for clearance. 7. Lower the vehicle and reconnect the transaxle shift and clutch linkages, electrical connectors, and any other components that can be reached from under the hood. Make sure you reinstall any ground wires, since they are critical to the proper operation of the vehicle electrical system. Remove the engine holding fixture, if used. Install the battery negative cable last. 8. Make preliminary shift linkage adjustments, if necessary. The clutch linkage may also require adjustment. 9. Fill the transaxle with the proper type of lubricant. If the unit has a separate reservoir for differential lubricant, refill it also. 10. After everything has been reconnected, operate the clutch pedal to ensure that the clutch engages and disengages properly. Also, move the gearshift lever to check operation of the shift linkage. Then, start the engine and road test the vehicle. Make any linkage adjustments as needed and recheck the transaxle fluid level(s). Summary Manual transaxle repair is similar to rear-wheel drive manual transmission repair. Since transaxles have mechani- cal parts, most will eventually wear out. In many cases, the transaxle will develop problems prematurely because of abuse or neglect. Most manual transaxle problems are easy to find if logical troubleshooting procedures are followed. The technician must carefully analyze the symptoms to find the exact problem. Safety should always come first when working on the vehicle. Support the front suspension when driving the vehi- cle on a lift, so that the CV axles are not damaged. When road testing, always obey traffic laws and try to use roads that are not congested. Some transaxle parts can be replaced without removing the transaxle from the vehicle. Before beginning transaxle removal, disconnect the battery negative cable. When remov- ing the CV axles, be careful not to damage them. Once the transaxle is removed from the vehicle, it should be installed securely on a clean workbench. The external parts should be removed before the case halves or end covers are removed. Once the case halves are removed, the gears and shift linkages can be disassembled. The differ- ential assembly should also be disassembled for inspection. Inspect all parts for wear and damage. Check the shafts, gears, and bearings. Any defective parts should be replaced. Reassemble the transaxle carefully, following all manufacturers’ instructions. If the transaxle gears bind or do not shift easily after reassembly, find and correct the problem. Do not expect binding parts to wear in! Reinstall the transaxle carefully. Make sure the CV axles are carefully installed to prevent damage. Refill the unit with fluid and adjust the clutch and shift linkages before test-driving the vehicle. Review Questions—Chapter 11 Answer the following questions using the information provided in this chapter. 1. You should always begin diagnosing manual transaxle problems by _____. (A) checking the level of the lubricant (B) adjusting the shift linkage (C) test-driving the vehicle (D) finding out why the vehicle was brought in for service 2. What are two relatively minor procedures that solve many manual transaxle problems? 3. Before assuming a transaxle is leaking lubricant, what should you consider? 4. _____ occurs when some outside force overcomes spring pressure in one of the detent holding mechanisms of the shift linkage. 5. What are some conditions that can cause gear slipout? 6. Which of the following would be the least likely cause of transaxle gear clash? (A) Misadjusted clutch. (B) Worn shift linkage. (C) Low lubricant level. (D) Damaged synchronizers. 7. A defective _____ gear may cause noise in every gear when the vehicle is moving.