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Manual Transmissions Common Installation Issues

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Manual Transmissions Common Installation Issues

DT#44207

Contamination Issue # 1

Symptom

  1. Decreased engine performance
  2. Shifting erratically
  3. Sticking valves
  4. Excessive heat
  5. Repeat failures
     

Cause

Contamination caused by not properly flushing the cooler

Preventative Action

Flush the transmission cooler as part of the installation process

Contamination Issue # 2

Symptom

  1. Excessive heat
  2. Premature bearing failure
  3. Oil breakdown
  4. Grinding in high & low
  5. Oil leaking from breather

Cause

Defective cooler Contamination due to not flushing cooler Mixed lubricants Antifreeze or water in heat exchanger leaking into transmission Glyco causes synchro lining to come off.

Preventative Action

Flush system prior to installing the remanufactured unit. Utilize a new oil cooler and/or heat exchanger.

PTO Interface

Symptom

  1. Hard shifting
  2. Noise
  3. Premature transmission failure

Cause

Improper cleaning of used PTO Failure to use a new PTO reseal kit Failure to set backlash properly (.006-.012).

Preventative Action

Clean PTO inside and outside. Inspect for wear, replace seal. Mount using PTO gasket shims & cooper washers on bolts.

Lubrication

Symptom

  1. Noise
  2. Excessive heat
     

Cause

Failure to use approved lubricants Failure to top off lubricants Failure to road test and recheck Mixed fluids in system.

Preventative Action

Follow recommended practices Know approved lubricants for all Drive Train components.

Driveline & Suspension

Symptom

  1. Vibration
  2. Noise
  3. Grinding
  4. Component failure
     

Cause

Failure to inspect driveline and suspension components for systems deficiencies.

Preventative Action

Perform inspection prior to putting the vehicle in service Practice standard maintenance intervals.

Component failures due to vibration – vibration caused by faulty driveline/suspension