This will help you fix own car

1. TOYOZU TECHNICAL SCHOOL
FOUNDATION, INC.
ATS NC II TRAINING SESSION
Batch 2021

2. OPENING PRAYER
Lord, help us in our online studies today. Give us
concentration so that may we listen, understand,
learn and have peaceful mind and may we always
remember that god is always with us

3. GOOD
MORNING!
TTSFI ATS NC II TRAINEES

4. LESSON:
COMMON TROUBLES OF MANUAL
TRANSMISSION

5. ATS NC II TRAINING SESSION
Objectives:
 Explain the common troubles of manual
transmission

6. LESSON:
COMMON TROUBLES OF MANUAL
TRANSMISSION

7. INTRODUCTION
Manual transmission issues can
develop because of high mileage, abuse, or
lack of proper maintenance, however,
they’re rather rare.

8. INTRODUCTION
Most manual transmission
problems originate not with the transmission
itself, but from connected parts like the
clutch assembly, linkage, or driveline: the
parts that transmit turning power from the
transmission to the wheels.

9. COMMON TROUBLES
OF
MANUAL
TRANSMISSION

10. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
a. Shift shaft
interlocks binding
a. Free

13. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
b. Clutch cable not
adjusted
properly
b. Check; Adjust
or Replace

16. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
c. Bent or worn
shift fork
c. Replace

19. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
d. Worn shift
shaft/rail
d. Replace

22. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
e. Gear or
synchronizer
sleeve tight on
shaft or splines
e. Replace worn
parts

26. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
f. Worn
synchronizer
rings or springs
f. Replace worn
parts

33. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
g. Worn or stripped
external teeth on
gear
g. Replace gear

38. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
h. Input shaft or
pilot bearing
binding
h. Replace pilot
bearing or
input shaft

43. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
i. Low lubricant
level
i. Fill to proper
level

48. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
1.Hard shifting into
gear
j. Improper
lubricant used
(particularly cold)
j. Drain and
refill with
specified
lubricant

51. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
2. Transmission
sticks in gear
a. Shift shaft or
interlock binding
a. Free

54. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
2. Transmission
sticks in gear
b. Shift detent
sticking
b. Free

57. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
2. Transmission
sticks in gear
c. Clutch not
disengage
c. Repair clutch
cable

60. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
2. Transmission
sticks in gear
d. Synchronizer
binding
d. Replace
synchronizer

63. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
2. Transmission
sticks in gear
e. Low lubricant
level
e. Fill to proper
level

64. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
a. Weak detent
spring
a.Replace

68. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
b. Worn input or
output shaft
bearing
b. Replace

73. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
c. Worn pilot
bearing
c. Replace

75. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
d. Excessive shaft
or gear endplay
d. Replace worn
thrust washer

79. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
e. Worn
synchronizer
sleeve
e. Replace
synchronizer
and gear

82. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
f. Loose or broken
input shaft
retainer
f. Replace

85. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
g. Loose
transmission or
clutch housing
g. Tighten
loosen bolt

87. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
3. Transmission
jumps out of
gear
h. Misaligned
transmission
h. Check
alignment

92. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
4. Gear clash when
shifting
a. Worn
synchronizer
a.Replace

93. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
4. Gear clash when
shifting
b. Clutch dragging b. Repair clutch

100. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
4. Gear clash when
shifting
c. Pilot bearing or
input shaft
binding
c. Replace
bearing or
shaft

101. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
4. Gear clash when
shifting
d. High engine idle
speed
d. Adjust

102. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
4. Gear clash when
shifting
e. Low lubricant
level or improper
lubricant
e. Fill with
correct
lubricant to
proper level

103. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
a. Defective clutch
disc
a.Replace

108. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
b. Excessive
clearance
between gears
and main shaft
b. Replace worn
gears or shaft

110. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
c. Worn defective
bearings
c. Replace

114. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
d. Broken gear
tooth
d. Replace gear

118. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
e. Worn
speedometer
pinion gear
e. Replace

121. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
f. Worn
synchronizer
f. Replace

122. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
g. Worn pilot
bearing
g. Replace

123. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
h. Low lubricant
level
h. Fill to proper
level

124. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
i. Transmission
misaligned
i. Check
alignment

125. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
5. Transmission
noisy in gear
j. Worn
countershaft
bearing or thrust
washer
j. Replace worn
parts

128. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
6. Transmission in
neutral
a. Worn input shaft
bearing
a.Replace

129. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
6. Transmission in
neutral
b. Broken or worn
gear
b. Replace

130. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
7. Transmission
noisy in reverse
a. Reverse idler
gear or shaft
bushing worn or
damaged
a.Replace

134. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
7. Transmission
noisy in reverse
b. Reverse gear
on main shaft
worn or
damaged
b. Replace

137. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
7. Transmission
noisy in reverse
c. Counter gear
worn or
damaged
c. Replace

138. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
7. Transmission
noisy in reverse
d. Shift
mechanism
damaged
d. Repair,
replace
defective
parts,
readjust

142. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
8. No power
through
transmission
a. Clutch not
engaging
a.Repair clutch

143. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
8. No power
through
transmission
b. Striped gear
teeth
b. Replace gear

144. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
8. No power
through
transmission
c. Loose or broken
shift fork
c. Replace

145. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
8. No power
through
transmission
d. Broken input or
output shaft
d. Replace

146. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
a. Incorrect
lubricant or
lubricant level too
high, causing
foaming
a.Fill with
specified
lubricant with
proper level

147. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
b. Leaking gasket b. Replace

150. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
c. Damaged oil
seal
c. Replace

152. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
d. Damaged oil
slinger
d. Replace

155. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
e. Loose fill plug e. Tighten

157. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
f. Speedometer
pinion seals
leaking
f. Replace seals

160. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
g. Cracked case or
extension
housing
g. Replace

164. MANUAL TRANSMISSION
TROUBLESHOOTING CHART
CONDITION POSSIBLE CAUSE CHECK or
CORRECTION
9. Transmission oil
leaks
h. Worn extension
housing seal or
bushing
h. Replace

166. DONE……

167. LET’S
HAVE AN
OPEN
FORUM

168. THANK
YOU!!!