Diagnosis By Symptom

TRANSMISSION SHIFT EFFORT INSPECTION PROCEDURE
1. Remove the shift rods at the transmission and align the sleeve, blocker ring and gear by shifting into the offending gear and then back into neutral.

2. Check the torque required to shift into gear with an inch pound torque wrench on the shift lever attaching bolt. If more than the specified torque is required (72 in. lbs. Max.), the transmission shift lever should be checked for rust or dirt binding the lever.

3. Clean levers, lubricate and recheck the torque value.

4. If at this point in the procedure, it is found that high shift effort still exists, an anti-chatter lubricant (positraction additive) may be used. The lubricant is available in a small plastic bottle and can be squirted into the transmission through the filler plug.

TRANSMISSION INTERNAL PROBLEMS RELATED TO SHIFT EFFORT
When the above procedures have been checked and the problem still exists, the transmission will have to be removed and disassembled for further diagnosis. There are three basic types of transmission internal problems reflected by shifting effort.

1. Hard Shifting - The effort to shift is excessive, but the gears engage. The lever moves with excessive effort throughout the entire travel range. If the static shift effort is high, (clutch depressed, engine not running), the synchronizer sleeve and hubs should be checked for a tight fit. With the three synchronizer keys removed, the sleeve should be loose on the hub. If the hub and sleeve are not a loose fit, replace the synchronizer assembly.

2. Blockout - The lever moves freely until the synchronizer is engaged. Synchronization should be heard to take place, but the gear will not engage. When it does engage, a double bump is generally felt in the lever. The synchronized blocker ring can be damaged by excessive force on gear cones that are finished improperly. The blocker ring material may stick to the synchronizer gear cone causing it to be a yellowish brass color, in streaks, which results in hard shifts when present. The gear cone should be a bright silver color. Polish the gear cone with 400 grit paper to a bright silver when the condition is present. The blocker rings should be replaced if the thread is damaged or worn.

3. Clash - Gear clash is a sound which sometimes occurs when the sleeve and gear chamfers contact each other in the unsynchronized state. The characteristics of clash are a grating or loud buzzing sound from the transmission. The shift lever load will be lower, but a vibration should be felt. The noise (clash) can be for a short instant or long enough to keep the gear from being engaged. This condition should not be confused with hard shifting or reported as such. Hard shifting and clash are directly opposite conditions. When the clash is slight, the load will build up on the shift lever and then fall off rapidly followed by the grating sound. If the transmission has been clashing, the sleeve ends should be examined for chipping and burrs. If the sleeves are damaged, the synchronizer assemblies and blocker rings should be replaced. Synchronizer sleeve ends should have an angular surface. The surfaces should be even from side to side and the radii indicated should be very small. Any chipping will require synchronizer replacement. Check the synchronizer load. When the keys are installed, the spring ends on one side of the hub should be hooked in one key and the spring on the opposite side of the synchronizer should not be hooked on the same key. A definite load should be felt when the sleeve is moved on the hubs with the keys and springs in proper position.