Subaru Crosstrek Service Manual: General diagnostic table Inspection
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > General Diagnostic Table
INSPECTION
1. MANUAL TRANSMISSION
Symptoms | Possible cause | Corrective action |
1. Gears are difficult to intermesh. NOTE: |
The cause for difficulty in shifting gears can be classified into two types: One is a defective gear shift system and the other is defective transmission. However, if the operation is heavy and engagement of the gears is difficult, a 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 at internal spline of the sleeve and reverse driven gear
Replace.
(b) Worn, damaged or burred chamfer of gear spline
Replace.
(c) Worn or scratched bushings
Replace.
(d) Incorrect contact or wear between baulk ring and gear cone
Repair or replace.
2. Gear slip-out
• Gear slips out when coasting on rough road.
• Gear slips out during acceleration.
(a) Defective pitching stopper adjustment
Replace.
(b) Loose engine mounting bolts
Tighten.
(c) Worn shifter fork or broken shifter check ball spring
Replace.
(d) Worn or damaged ball bearing
Replace.
(e) Excessive clearance between splines of synchronizer hub and synchronizer sleeve
Replace.
(f) Synchronizer hub tooth step wear
Replace.
(g) Worn 1st driven gear and driven shaft
Replace.
(h) Worn 2nd driven gear and bushing
Replace.
(i) Worn 3rd drive gear and needle bearing
Replace.
(j) Worn 4th drive gear and needle bearing
Replace.
(k) Worn 5th drive gear and needle bearing
Replace.
(l) Worn reverse idler gear and bushing
Replace.
3. Noise emitted from transmission
NOTE:
If a noise is heard when the vehicle is parked with its engine idling and if a noise ceases when the clutch is disengaged, it may be considered that the noise is coming from the transmission.
(a) Insufficient or improper lubrication
Lubricate with specified oil or replace.
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the gear teeth surfaces, only a high whirring noise will occur at high speeds, but if any part is broken, rhythmical clicking sounds will be heard even at low speeds.
Replace.
2. DIFFERENTIAL
Symptoms | Possible cause | Corrective action |
1. Broken differential (case, gear, bearing, etc.) NOTE: |
Noise will occur, and eventually the differential will not be able to operate due to broken pieces obstructing the gear revolution.
(a) Insufficient or improper oil
Disassemble the differential and replace broken components. At the same time check other components for any trouble, and replace if necessary.
(b) Use of vehicle under severe conditions such as excessive load and improper use of the clutch
Readjust the preload and backlash of the bearing, and the contact surface of gear.
(c) Improper adjustment of taper roller bearing
Adjust.
(d) Improper adjustment of the drive pinion and the hypoid driven gear
Adjust.
(e) Excessive backlash of a vehicle under severe operating conditions due to worn differential side gear, adjusting washer or differential pinion
Add recommended oil to the specified level. Do not use vehicle under severe operating conditions.
(f) Loose hypoid driven gear clamping bolts
Tighten.
2. Differential and hypoid gear noises
Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of trouble. However, noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the following four kinds of noises.
• Gear noise when driving:
If noise increases as the vehicle speed increases, it may be due to insufficient gear oil, incorrect gear engagement, damaged gears, etc.
• Gear noise when coasting:
Damaged gears due to misadjusted bearings and incorrect shim adjustment
• Bearing noise when driving or coasting:
Cracked, broken or damaged bearings
• Noise mainly when turning:
Noise from differential side gear, differential pinion or differential pinion shaft, etc.
(a) Insufficient oil
Replenish or replace with the specified amount of recommended oil.
(b) Improper adjustment of hypoid driven gear and drive pinion
Check the tooth contact.
(c) Worn teeth of hypoid driven gear and drive pinion
Replace as a set.
Readjust the bearing preload.
(d) Loose roller bearing
Readjust the backlash of the hypoid driven gear to drive pinion, and check the tooth contact.
(e) Distorted hypoid driven gear or differential case
Replace.
(f) Worn adjusting washer and differential pinion shaft
Replace.
Installation
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