Repair Manual MAN-00
190
THAR
CRDe
BS-IV
MAY
2012
/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
Trouble Shooting
A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an
incorrect lubricant level check.
Leaks can occur at the mating surface of the gear case, intermediate plate and adapter or extension
housing or from the front/rear seals. A suspected leak could also be result of an overfill condition.
Leaks at the rear of the extension or adapter housing will be from the housing oil seal. Leaks at
component mating surface will probably be the result of inadequate sealer, gaps in sealer, incorrect
bolt tightening, or the use of a non-recommended sealer.
A leak at the front of the transmission will be from either the front bearing retainer or retainer seal.
Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe,
it may also contaminate the clutch disc causing slip, grab and chatter.
A correct lubricant level check can be made only when the vehicle is level, use a two post or a four
post hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These
recommendations will ensure that an accurate check and avoid an under fill or overfill conditions.
Hard Shifting
Hard shifting is usually caused by low lubricant level, improper or contaminated lubricants,
component damage, and incorrect clutch adjustment or by a damaged clutch pressure plate or disc; or
worn out brass synchro ring.
Substantial lubricant leak can result in gear, shift rail, synchro and bearing damage. If a leak goes
undetected for an extended period the first indications of a problem are usually hard shifting and
noise.
Improper clutch release is one of the most frequent causes of hard shifting. Incorrect adjustment of a
worn damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced
then gear clash during shifts can be resulted. Incomplete travel of the clutch pedal due to restrictions
at the end of stroke (upturned carpet, extra carpet or cover or bend clutch linkage can also cause
improper clutch release and hard shift.)
Worn or damaged synchro rings can cause gear clash when shifting any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most
conditions this will decline as the rings wear in.
Transmission noise
Most manual transmissions make some noise during normal operation. Rotating gears can generate
slight whine that may only be audible at extreme speeds.
Severe obviously audible transmission noise is generally the result of a lubricant problem. Insufficient,
improper or contaminated lubricant can promote rapid wear of gears, synchros, shift rail, forks and
bearing’s. The overheating caused by a lubricant problem can also lead to gear breakage.
Page 147
