Transmission - Suzuki Samurai 1986 Service Manual

Condition
Dragging clutch
Clutch vibration
Noisy clutch
Grabbing clutch

2-5. TRANSMISSION

Condition
Gears slipping out of
mesh
Gears refusing to dis-
engage
2-10
Possible cause
1. Improper clutch pedal free travel
2. Weakened diaphragm spring, or worn spring
tip
3. Damaged or worn splines of transmission
input shaft
4. Front input shaft bearing worn or broken
5. Excessively wobbly clutch disc
6. Clutch facings broken or dirty with oil
1. Glazed (glass-like) clutch facings
2. Clutch facings dirty with oil
3. Wobbly clutch disc, or poor facing contact
4. Weakened torsion springs (in clutchdisc)
5. Clutch disc rivets loose
6. Distorted pressure plate or flywheel surface
7. Weakened engine mounting or loosened
mounting bolt or nut
1. Worn or broken release bearing
2. Front input shaft bearing worn down
3. Excessive rattle of clutch disc hub
4. Cracked clutch disc
5. Pressure plate and diaphragm spring rattling
1. Clutch facings soaked with oil
2. Excessively worn clutch facings
3. Rivet heads showing out of the facing
4. Weakened torsion springs
Possible cause
1. Worn shift fork shaft
2. Worn locating steel balls
3. Weakened springs for locating steel balls
4. Worn shift fork
5. Excessive rattle in thrust direction of gears
6. Worn ring or hub in synchronizers
7. Worn bearings of input shaft, main shaft or
countershaft
1. Weakened or broken synchronizer springs
2. Worn inner groove of synchronizer ring
3. Synchronizer ring seized on. the cone
4. Distorted shift fork shaft or shift fork
Correction
Adjust free travel
Replace
Replace
Replace
Replace
Replace
Repair or replace
Replace
Replace
Replace
Replace the disc
Replace
Retighten or replace
Replace
Replace
Replace the disc
Replace
Replace
Replace
Replace
Replace
Replace
Correction
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace the ring
Replace.