For 1990-2009 cars

### Diagnostic Aids

An intermittent hard shift may be caused by an intermittent clutch condition. With a self adjusting clutch, the clutch may be between adjustments and not give full clutch release. This might be felt by a low clutch pedal. After several applications, the clutch may adjust properly to give the proper pedal feel.

### 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 of the gear positions with the engine not operating. While performing the test, one should note how the shift lever movement is felt. Also while shifting from one gear to the other, feel for binding in the shift rails. You should be able to feel the detent plungers operating when coming out of a gear and when going into a gear.

2. A dynamic shift test is performed by shifting into one of the gear positions with the engine operating. Test for the correct mesh of the synchronizers and for the clutch releasing correctly. When shifting into a gear, and shifting out of a gear, you should feel the shift detent plungers operating, and the synchronizer sleeve moving freely.

3. The transmission uses DEXRON® III transmission fluid that allows proper synchronizer operation. The incorrect fluid may cause hard shifting from varnish build up, or from not enough lubrication for proper synchronizer operation.

Step | Action | Yes | No
--- | --- | --- | ---
DEFINITION: The transmission does not shift smoothly or without difficulty from one gear to the other.
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 | Inspect the clutch system for proper operation. Refer to Clutch System Description and Operation. Did you find or repair the condition? | Go to Step 11 | Go to Step 3
3 |

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

• | Blockage preventing full shift lever movement.

• | Excessive movement in the shift lever.

• | Binding in the shift lever.

• | Detent plungers or shift rails binding.

• | Shift linkage binding.

• | Shift linkage proper adjustment.

Are you able to shift into all gears?

Go to Step 7

Go to Step 4

4 | 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 11

Go to Step 5

5 |

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

• | Detent plungers or shift rails binding.

• | Synchronizer sleeve binding.

• | Gear clash into only one gear.

• | Gear clash into all gears.

Did the transmission shift hard into all gears?

Go to Step 6

Go to Step 10

6 | Inspect the transmission for the correct fluid level and the correct type of transmission fluid. Refer to Transmission Fluid Replacement. Is the transmission at the correct level and proper fluid being used? | Go to Step 8 | Go to Step 7
7 | Drain and fill the transmission with the correct type fluid. Refer to Transmission Fluid Replacement Did you find and repair the condition? | Go to Step 11 | Go to Step 8
8 | Remove the transmission. Refer to Transmission Replacement. Inspect the clutch pressure plate and/or clutch driven plate. Is the clutch pressure plate and/or clutch driven plate worn or faulty? | Go to Step 9 | Go to Step 10
9 | Replace the clutch assembly. Refer to Clutch Assembly Replacement. Did you find and repair the condition? | Go to Step 11 | Go to Step 10
10 |

1. Disassemble the transmission. Refer to Transmission Disassemble.
2. Inspect the transmission for the following faulty components in the gear that is hard to shift or clashing:

• | Excessive synchronises blocking ring to gear clearance.

• | Synchroniser hub external splines worn or damaged.

• | Excessive axial clearance in the speed gear.

• | Mainshaft to speed gear bearing or journal worn.

• | Shift rail and the internal shift control lever components for wear or damage.

3. Replace worn or damaged components as necessary.

Did you find and repair the condition?

Go to Step 10

Go to Diagnostic Aids

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