Diagnostic Information And Procedures - SSANGYONG 2004 Rexton 2.7XDi Workshop Manual

DIAGNOSTIC INFORMATION AND PROCEDURES

Trouble Diagnosis
Symptom
Will not shift
(control lever moves)
Hard shift or control
lever will not move into
gear
Gears crash when
shifting
Transmission jumps
out
Transmission locked in
one gear
TSM54/52 MANUAL TRANSMISSION
REXTON SM - 2004.4
Cause
Control lever assembly broken or
damaged.
Damaged offset lever, shift fork, selector
place or selector arm.
Clutch not releasing.
Improper or low transmission oil.
Shift or shift rail binding.
Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch.
Worn or damaged flywheel pilot bushing.
Engine idle speed too high.
Damaged or faulty clutch.
Pilot bearing between input shaft and
output shaft binding.
Damaged synchronizer.
Bell housing misaligned.
Damaged gear(s).
Worn or damaged flywheel pilot bushing.
Loosened transmission or flywheel housing
bolts, improper alignment.
Synchronizer damaged or excessively
worn.
Blocking ring damaged, worn index slots or
friction surfaces worn or damaged.
Excessive countershaft end play.
Worn or damaged fork due to loosened
shaft, rail or shifting fork.
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever, shaft
or rail.
Action
Replace control lever and housing
assembly.
Remove extension, adapter or case cover.
Check or replace damaged parts.
Adjust or replace clutch.
Add or replace with specified oil.
Remove extension, adapter or case cover.
Check or replace damaged parts.
Remove extension, adapter or case cover.
Check synchronizers and gears and
replace damaged parts.
Check or replace backup switch.
Replace pilot bushing.
Adjust idle speed to specified speed.
Adjust or replace clutch.
Replace or check roller bearings.
Check or replace synchronizer parts.
Align bell housing and bore.
Check or replace gear(s).
Replace pilot bushing.
Tighten bolts to specified value. Realign if
necessary.
Check or replace synchronizer parts.
Check or replace blocking ring.
Check worn or damaged parts. Adjust
shim thickness using roller bearings if
necessary.
Check for wear or damaged. Replace worn
or damaged parts.
Replace extension, adapter or case cover.
Check or replace loose parts on shaft or
rail. Replace roll pin(s).
Remove extension, adapter or case cover.
Check for wear or damaged. Replace
damaged parts.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
3B-25