For 1990-2009 cars

### Diagnostic Aids

If the transmission jumps out of gear during deceleration, inspect the components that may allow for the gears or shafts to tip. If the gears or shafts tip, the synchronizer sleeve can disengage from the selector teeth on the speed gear. If the transmission jumps out of gear during acceleration, inspect the components that may not allow full engagement of the synchroniser sleeve to the selector teeth on the speed gear. Insufficient engagement of the selector teeth under torque may cause the transmission to jump out of gear.

### Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. A static shift test is performed by shifting into all gear positions with the engine not operating. While performing the test, slowly move the shift lever. Feel for proper movement of the shift lever and transmission internal shift components.

2. A dynamic shift test is performed by shifting into all gear positions with the engine operating. Test for the correct mesh of the synchroniser sleeve and the speed gear selector teeth. Move the shift lever, and feel for the synchroniser sleeve to release from the gear, then let up on the clutch pedal. Depress the clutch pedal and move the shift lever to engage the gear again, to Make sure full travel of the shift components.

3. This step inspects for worn or damaged transmission or engine mounts. Loose mounts may cause a shock on the transmission allowing for gear disengagement.

4. This step inspects for the misalignment of the torque tube to transmission. Misalignment may put a bind on the input shaft, allowing for the input shaft or the mainshaft to tip.

5. This step inspects the pilot bearing and the pilot bearing journal on the input shaft. A worn pilot bearing or input shaft may allow the input shaft to tip, causing gear disengagement.

Step | Action | Yes | No
--- | --- | --- | ---
DEFINITION: Gear disengagement occurs during acceleration or deceleration.
1 | Did you review the operations and perform the necessary inspections? Refer to Symptoms - Manual Transmission | Go to Step 2 | Go to Symptoms - Manual Transmission
2 |

1. Perform a static shift test.
2. Test for the following conditions:

• | Blockage preventing full shift lever movement.

• | Excessive movement in the shift lever.

• | Detent plungers engaging in the shift rails.

• | Synchroniser pressure pieces on the synchronizser sleeves.

• | Shift linkage binding.

• | Shift linkage proper adjustment.

Did the transmission shift completely into all gears?

Go to Step 5

Go to Step 3

3 | Remove the shift control shift closeout boot. Refer to Shift Control Shift Closeout Boot Replacement. Inspect for the following:

• | Loose mounting.

• | Foreign debris.

Did you find and repair the condition?

Go to Step 10

Go to Step 4

4 |

1. Perform a dynamic shift test on the transmission.
2. Test for the following conditions:

• | Synchroniser sleeve engagement to the speed gear selector teeth.

• | Detent plungers engaging in the shift rails.

Did the transmission shift completely into all gears?

Go to Step 5

Go to Step 8

5 | Inspect the engine and/or transmission mounts. Refer to Transmission Mount Inspection. Did you find and repair the condition? | Go to Step 10 | Go to Step 6
6 | Inspect the clutch housing for loose retaining bolts or misalignment. Are there any loose bolts or misalignment? | Go to Step 9 | Go to Step 8
7 | Tighten any loose housing retaining bolts and/or align the housing . Refer to Clutch Assembly Replacement Did you find and repair the condition? | Go to Step 10 | Go to Step 8
8 |

1. Remove the transmission. Refer to Transmission Replacement
2. Remove the clutch assembly. Refer to Clutch Assembly Replacement.
3. Inspect the pilot bearing for being faulty.
4. Inspect the input shaft for excessive wear at the pilot bearing.

Did you find and repair the condition?

Go to Step 10

Go to Step 9

9 |

1. Disassemble the transmission. Refer to Transmission Disassemble.
2. Inspect the following components for wear or damage:

• | The shift rails.

• | The detent plungers and springs.

• | The shift forks.

• | The synchroniser sleeve and speed gear selector teeth.

• | The mainshaft to input shaft bearing and journals.

• | The speed gear bearings and journals.

• | The speed gear axial clearance.

• | The mainshaft center and rear bearings.

Did you find and repair the condition?

Go to Step 10

Go to Diagnostic Aids

10 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 1