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Manual Transmissions Common Installation Issues

DT#44207

Contamination Issue # 1

Symptom
  1. Decreased engine performance
  2. Shifting erratically
  3. Sticking valves
  4. Excessive heat
  5. Repeat failures
Cause
Contamination caused by not properly flushing the cooler
Preventative Action
Flush the transmission cooler as part of the installation process
common installation issues

Contamination Issue # 2

Symptom
  1. Excessive heat
  2. Premature bearing failure
  3. Oil breakdown
  4. Grinding in high & low
  5. Oil leaking from breather
Cause
Defective cooler Contamination due to not flushing cooler Mixed lubricants Antifreeze or water in heat exchanger leaking into transmission Glyco causes synchro lining to come off
Preventative Action
Flush system prior to installing the remanufactured unit. Utilize a new oil cooler and/or heat exchanger
common installation issues

PTO Interface

Symptom
  1. Hard shifting
  2. Noise
  3. Premature transmission failure
Cause
Improper cleaning of used PTO Failure to use a new PTO reseal kit Failure to set backlash properly (.006-.012)
Preventative Action
Clean PTO inside and outside. Inspect for wear, replace seal. Mount using PTO gasket shims & cooper washers on bolts
common installation issues

Lubrication

Symptom
  1. Noise
  2. Excessive heat
Cause
Failure to use approved lubricants Failure to top off lubricants Failure to road test and recheck Mixed fluids in system
Preventative Action
Follow recommended practices Know approved lubricants for all Drive Train components
common installation issues

Driveline & Suspension

Symptom
  1. Vibration
  2. Noise
  3. Grinding
  4. Component failure
Cause
Failure to inspect driveline and suspension components for systems deficiencies
Preventative Action
Perform inspection prior to putting the vehicle in service Practice standard maintenance intervals
common installation issues

Component failures due to vibration - vibration caused by faulty driveline/suspension

common installation issues



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