Subaru 1600 Service Manual page 290

MANUAL TRANSMISSION ANO 01 FFERENTIAL
2. Manual Transmission and Differential
Condition and possible cause Corrective action
I. Gears are difficult to intermesh.
The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift
system and the other is malfunction of the transmission.
However. if the operation is heavy and engagement of the gears is difficult. defective clutch disengagement may
also be responsible. Check whether the clutch is correctly functioning. before checking the gear shift system and
transmission.
(a) Worn. damaged or burred chamfer of internal
spline of sleeve and reverse driven gear.
(b) Worn. damaged or burred chamfer of spline of
gears.
(c) Worn or scratched bushings.
(d) Incorrect contact between synchronizer ring
and gear cone or wear.
2. Gear slips out.
(1) Gear slips out when coasting on rough road.
(2) Gear slips out during acceleration.
(a) Defective pitching stopper adjustment.
(b) Loose engine mounting bolts.
(c) Worn fork shifter. broken shifter fork rail
spring.
(d) Worn or damaged ball bearing.
(e) Excessive clearance between splines of synchro-
nizer hub and synchronizer sleeve.
(f) Worn tooth step of synchronizer hub (respon-
sible for slip-out of 3rd gear).
(g) Worn 1st driven gear, needle bearing and race.
(h) Worn 2nd driven gear, needle bearing and race.
(0 Worn 3rd drive gear and bushing.
(j) Worn 4th drive gear and bushing.
(k) Worn reverse idler gear and bushing.
3. Unusual noise from transmission.
Replace.
Replace.
Replace.
Correct or replace.
Adjust.
Tighten or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
If an unusual noise is heard when the car is parked with its engine idling and if the noise ceases when the clutch is
disengaged, it may be considered that the noise comes from the transmission.
(a) Insufficient or improper lubrication.
(b) Worn or damaged gears and bearings.
(NOTE)
If the trouble is only wear of the tooth surfaces,
merely a high roaring noise will occur at high
speeds, but if any part is broken, rhythmical
knocking sound will be heard even at low speeds.
Lubricate or replace with specified oil.
Replace.
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