For 1990-2009 cars

1. Verify/duplicate the customer concern. If the customer concern can be duplicated, proceed to step 2.
2. Perform the following input shaft spin down test.

2.1. | Set the parking brake and place the vehicle in neutral.

2.2. | Start the engine and allow the vehicle to idle.

2.3. | Gently move the shifter toward the reverse gate and continue to move the shifter until a light grind/rattle can be heard.

2.4. | Once the grind/rattle noise is observed, depress the clutch pedal and note the time required for the grind/rattle noise to stop. Normal spin down time, time required until grinding noise stops, is approximately 3 seconds.

• | If the noise stops, input shaft stops spinning, within approximately 3 seconds, the clutch disc/pressure plate and clutch hydraulic system are not the cause of the hard to shift into gear or grind into gear concern. Proceed to step 3.

• | If the noise does not stop within 3, inspect the clutch pedal travel and clutch fork travel as described below.

- | Clutch Pedal Travel Measurement

- | Measure the clutch pedal travel refer to Clutch Hydraulic System Diagnosis . Pedal travel should be between 117-137 mm (4.6-5.4 in). If the clutch pedal travel is not between 117-137 mm (4.6-5.4 in), check for:

• | Carpet or floor mat under pedal.

• | Faulty bushing/damaged pedal.

- | Clutch Fork Travel Measurement

- | Measure the clutch fork travel refer to Clutch Hydraulic System Diagnosis . If the clutch fork travel is less than 10.80 mm (0.43 in) check for the following:

| Important: The first four bullets require master/slave cylinder replacement.

• | Fluid leak in hydraulic system

• | Damage to the front of the dash

• | Air in system

• | Damaged master/slave cylinder

• | Master/slave cylinder improperly installed

- | If pedal travel and fork travel are OK and clutch hydraulics are functioning properly, check for:

• | Bent fork

• | Damaged pressure plate and/or clutch disc

3. Attempt to verify the hard to shift into the gear concern with the engine OFF.

• | If the concern is not observed with the engine OFF, check for:

- | Damaged blocker ring, blocker ring teeth rounded off.

- | Burnt blocker ring/blocker ring friction material debonded.

- | Oversized blocker ring, can check with feeler gage for clearance between the blocker and the gear.

- | Missing circular spring.

- | Worn or damaged shift fork pad/bushing

- | Synchronizer sleeve tooth points damaged.

• | If the concern is observed with the engine off, check for :

- | Shift cable retainer clip loose/missing

- | Damaged/kinked shift cable.

- | Damaged shift tower components.

- | Shifter assembly damaged/broken.