Manual Transmissions Common Installation Issues

DT#44207

Contamination Issue # 1

Symptom

Decreased engine performance
Shifting erratically
Sticking valves
Excessive heat
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

Excessive heat
Premature bearing failure
Oil breakdown
Grinding in high & low
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

Hard shifting
Noise
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

Noise
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

Vibration
Noise
Grinding
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

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Manual Transmissions Common Installation Issues