For 1990-2009 cars

Complaint/Condition | Possible Causes | Corrections
--- | --- | ---
Fluid leakage | The fluid level is high. | Drain any excess fluid.
The shift control shaft spring loaded locking pin is leaking. | Remove the pin. Replace with the manual transaxle shift lever hole plug P/N 90105651. Verify the leak is eliminated.
The end cover is loose or the gasket is damaged. | Replace the gasket and tighten to specification. Add florescent dye to verify the leak is eliminated.
The case to clutch housing interface seal is damaged. | Apply sealant and tighten to specification. Add florescent dye to verify the leak is eliminated.
The axle seal is damaged. | Replace the axle seal. Add florescent dye to verify the leak is eliminated.
The input shaft seal is damaged. | Replace the clutch slave cylinder.
The shift control shaft seal is damaged. | Replace the seal. Add florescent dye to verify the leak is eliminated.
The back-up lamp switch is loose. | Remove the switch, inspect the gasket, and replace if necessary. Install the switch and tighten to specification. Verify the leak is eliminated.
Casting porosity | Add florescent dye to verify case leakage exists. Replace the case if necessary.
The reverse idler gear shaft bolt is loose, or the O-ring is damaged. | Remove the bolt, inspect the O-ring, and replace if necessary. Tighten the bolt to specification.
The reverse idler gear shaft bracket bolt is loose. | Tighten the bolt to specification. Verify the leak is eliminated.
Transaxle hops out of gear | There is operator error/incomplete shift travel. | Demonstrate the correct shifting.
The shift forks are worn. | Replace the shift fork.
The control shaft lever assembly is worn or damaged. | Replace the control shaft lever assembly.
The control assembly rod is out of adjustment. | Adjust the control assembly rod. Refer to "Shift Linkage Adjustment" in this service manual.
The control assembly is broken. | Replace the control assembly.
The manual transaxle internal shift mechanism malfunctions. | Disassemble the transaxle and repair as necessary.
Grinds during shifting or gear clashing | The blocking ring/gear is worn or burnt. | Replace the components. Check the clutch pedal travel.
The shift forks are worn. | Replace the shift fork.
The clutch is worn or damaged. | Inspect the clutch disc and replace if necessary. Follow the "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary.
Transaxle gear rattle in neutral | The clutch disc damper fails. | Replace the clutch disc.
The engine idle speed is low. | Correct the condition causing low idle speed.
Difficult to shift/block out (static/engine OFF) | The control assembly rod is out of adjustment. | Adjust the control assembly rod. Refer to "Shift Linkage Adjustment" in this service manual.
The manual transaxle internal shift mechanism malfunctions. | Disassemble the transaxle and repair as necessary.
The control shaft lever assembly is broken. | Replace the control shaft lever assembly.
The control assembly is damaged. | Replace the control assembly.
Difficult to shift/block out (dynamic/engine running) | The clutch is worn or damaged. | Inspect the clutch disc and replace if necessary. Follow the "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary.
The synchronizer/gear is worn. | Replace the components.
The shift fork is worn. | Replace the shift fork assembly.
The driven bushings (output shaft) is worn. | Replace the components.
The drive gear needle bearings (input shaft) are worn. | Replace the components.
The clutch is not releasing. | Verify clutch pedal travel and replace the clutch if necessary.
Difficult to shift/block out (general) | The shift fork is worn. | Replace the shift fork.
The control assembly rod is out of adjustment. | Adjust the control assembly rod. Refer to "Shift Linkage Adjustment" in this service manual.
The synchronizer sleeve tooth point is damaged. | Replace the synchronizer assembly.
The clutch is worn or damaged. | Inspect the clutch disc and replace if necessary. Follow the "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary.
The clutch is not releasing. | Verify the clutch pedal travel and replace the clutch if necessary.
Difficult to select gates | The control shaft lever assembly is broken. | Replace the control shaft lever assembly.
The shifter assembly is damaged. | Replace the shifter assembly.
Stuck in gear | The control shaft lever assembly is broken. | Replace the control shaft lever assembly.
The manual transaxle internal shift mechanism malfunctions. | Disassemble the transaxle and repair as necessary.
The shift fork is damaged. | Replace the shift fork assembly.
Vehicle does not move (stuck in 2 gears) | The manual transaxle internal shift mechanism malfunctions. | Disassemble the transaxle and repair as necessary.
Noisy shifting | The shifter assembly is damaged. | Inspect the shifter assembly and replace if necessary.
Noisy in neutral with the engine ON | The input shaft roller bearings are worn. | Inspect the roller bearings and replace if necessary.
The driven gear bushings (output shaft) are worn. | Inspect the components and replace if necessary.
The clutch slave cylinder are worn. | Inspect the release bearing and replace if necessary.
Noisy around turns | The differential gear is worn or damaged. | Inspect the differential gear and replace if necessary.
Noisy in all gears | The fluid level is low. | Add manual transaxle lubricant.
The drive gear needle bearings (input shaft) are worn. | Inspect the components and replace if necessary.
The driven gear bushings (output shaft) are worn. | Inspect the components and replace if necessary.
First, second, third, fourth, or fifth gears are chipped, scored, or worn. | Inspect the components and replace if necessary.
Noisy in first only | First gears are chipped, scored, or worn. | Inspect the first gears and replace if necessary.
The 1-2 synchronizer is damaged or worn. | Inspect the synchronizer and replace if necessary.
Noisy in second only | Second gears are chipped, scored, or worn. | Inspect the second gears and replace if necessary.
The 1-2 synchronizer is damaged or worn. | Inspect the synchronizer and replace if necessary.
Noisy in third only | Third gears are chipped, scored, or worn. | Inspect the third gears and replace if necessary.
The 3-4 synchronizer is damaged or worn. | Inspect the synchronizer and replace if necessary.
Noisy in fourth only | Fourth gears are chipped, scored, or worn. | Inspect the fourth gears and replace if necessary.
The 3-4 synchronizer is damaged or worn. | Inspect the synchronizer and replace if necessary.
Noisy in fifth only | Fifth gears are chipped, scored, or worn. | Inspect the fifth gears and replace if necessary.
The fifth synchronizer is damaged or worn. | Inspect the synchronizer and replace if necessary.
Noisy in reverse only | The reverse idler gear or idler bushing is worn or damaged. | Inspect the idler gear and bushing and replace if necessary.
The 1-2 synchronizer sleeve is damaged or worn. | Inspect the synchronizer and replace if necessary.