Suzuki Samurai 1986, Service Manual

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Condition
Excessive gear noise
Hard shifting
2-6. DIFFERENTIALS
Possible cause
1. Not enough oil in transmission
2. Defective synchronizer
3. Gears rattling in thrust direction
4. Broken or worn bearings
5. Damaged or worn gears
1. Clutch pedal play too large, resulting in a
“dragging clutch”
2. Worn clutch disc facings
3. Clutch disc facings dirty with oil.
4. Distorted or unevenly worn shift fork shaft
5. Broken locating balls
6. Worn synchornizer sleeve or ring
7. Worn synchronizer hub
C o n d i t i o n
Gear noise
Bearing noise
Possible cause
1. Maladjusted backlash between drive pinion
and ring gear
2. Damaged gear teeth or improper mesh of
drive pinion and ring gear
3. Improper tooth contact in the mesh between
drive pinion and ring gear
4. Insufficient or wrong kind of gear oil
5. Ring gear wobbling when turning, or ring
gear securing bolts loose
6. Broken or otherwise damaged teeth of side
gears or differential pinion gears
1. (Constant noise) Insufficient or wrong kind
of gear oil
2. (Constant noise) Damaged or worn bearings
or borne parts
3. (Noise during coasting) Damaged bearings
of rear drive pinion
4. (Noise during turning) Broken bearings
on axle shafts
Correction
Replenish
Replace
Replace
Replace
Replace
Adjust as prescribed
Replace.
Replace.
Replace
Replace
Replace
Replace
Correction
Adjust as prescribed
Replace or adjust
Adjust as prescribed
Replenish or replace
Replace, or retighten
Replace
Replenish or change
Replace.
Replace
Replace
2-11