Cushman TURF-TRUCKSTER, Service & Repair Manual

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DRIVE TRAIN
SECTION 4B. FAILURE ANALYSIS
4B-1
4B
PROBLEM PROBABLE CAUSE REMEDY
1. Noisy when vehicle a. Excessive gear backlash. a. Adjust (Section 4G or 4H).
moving forward or reverse.
b. Faulty U-joints. b. Repair (Section 4C).
2. Clunking sound when a. Axle drive U-joint faulty. a. Repair (Section 4C).
changing direction.
b. Excessive differential gear b. Adjust (Section 4I).
backlash.
3. Control lever moves but a. Control lever assembly broken a. Replace control lever or housing
will not shift. or damaged. assembly (Section 4G or 4H).
b. Damaged offset lever, shift fork, b. Remove shifter case cover. Check
selector plate or selector arm. for damaged parts. Replace
damaged parts (Section 4G).
4. Hard shift or control a. Clutch not releasing. a. Adjust or replace clutch
lever will not move (Section 4D).
into gear.
b. Improper or low transmission b. Add or drain and replace with
lubricant. proper lubricant (Section 11).
c. Shifter shaft or shift rail binding. c. Remove shifter case cover. Check
for damaged parts. Replace
damaged parts (Section 4G or 4H).
d. Binding of sliding synchronizer d. Remove shifter case cover. Check
or gears. that synchronizers and gears
(parts with shifting grooves) slide
freely on shafts. Remove and
replace damaged parts (Section
4G or 4H).
e. Reverse only, seized backup e. Remove and check backup switch.
switch. Replace if seized (Section 10).
5. Slipping clutch. a. Loss of clearance at the tip of a. Adjust (Section 4D).
release fork.
b. Clutch facings dirty with oil or b. Replace (Section 4D).
excessively worn.
c. Weakened diaphragm spring. c. Replace (Section 4D).
d. Distorted pressure plate or d. Replace (Section 4D).
flywheel surface.
e. Improper clutch pedal free travel. e. Adjust and/or replace clutch
facings (Section 4D).
6. Dragging clutch. a. Improper clutch pedal free travel. a. Adjust free travel (Section 4D).
b. Weakened diaphragm spring or b. Replace (Section 4D).
worn spring tip.
c. Damaged or worn splines of c. Replace (Section 4G or 4H).
transmission input shaft.
d. Front input shaft bearing worn or d. Replace (Section 4G or 4H).
broken.
e. Excessively wobbly clutch disc. e. Replace (Section 4D).
f. Clutch facings broken or dirty f. Replace (Section 4D).
with oil.