Inspection and Verification

Inspection and Verification

NOTE: If any evaluation or inspection reveals an obvious concern, repair the vehicle.

NOTE: Before attempting to rectify any concerns, road test the vehicle to ascertain in which system the concern falls.

NOTE: If transaxle noise is reported, first check the fluid level.

A gear driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions.

Certain conditions, such as, road and weather, will amplify normal vehicle noise.

The following overview is a guide to diagnose a transaxle/clutch concern:
^ Verify and document the customer concern.
- During the customer interview, if a leak was noticed or if a leak is the concern, check the transmission fluid. The vehicle should not be driven if the fluid level is low.
^ Check fluid level and condition.
^ Evaluation of the clutch hydraulic system.
^ Evaluation of the clutch.
^ Inspect gearshift mechanism.
^ Road test.
^ Find the cause of the problem and correct it.

Verify Customer Concern
1. Verify and document the customer concern.
1. When was it first noticed?
2. Did it appear suddenly or gradually?
3. Did anything unusual occur that would coincide with it or precede it?
4. Identify when the condition occurs:
^ Hot or cold vehicle operating conditions.
^ Type of terrain.
^ City/highway driving.
^ Driving at a particular speed.
- coasting.
- hard acceleration.
^ Shifting.
- upshifts.
- downshifts.
- in a particular gear.
- in all gears.
^ Hot or cold ambient temperatures.
5. Has the transaxle/clutch been repaired before or components installed?
^ Check the vehicle service record. Note any repairs.
6. Check TSBs.

Check Fluid Level and Condition

CAUTION: The vehicle should not be driven if the fluid level is low.

An incorrect level may affect the transaxle operation and can result in transaxle damage. To correctly check and add fluid to the transmission, refer to Specifications.

A low fluid level can result in poor transaxle shifting, engagement or damage. It can also indicate a leak in one of the transmission seals or gaskets.
1. Check the fluid condition.
^ Observe the color and the odor of the fluid. Allow the fluid to drip onto a white cloth and examine the stain. Check the fluid for contamination or metal particles.
^ Fluid should appear nearly clear, similar to clean engine oil.

Evaluation of Clutch Hydraulic System
1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
^ If the fluid level is correct, proceed to clutch check.
^ If the fluid level is low, add fluid as necessary. Check the clutch hydraulic system for leaks and repair as necessary.

Evaluation Of The Clutch
1. Depress and release the clutch pedal slowly to check if the pedal is binding. Make sure the clutch pedal can be fully depressed and is not restricted by the floor mat. Verify that the pedal return spring is present and functions correctly.
2. Measure the clutch reserve. GO to Pinpoint Test A. Test A: Clutch Slippage
3. With the engine idling, the parking brake on and the clutch pedal up, gently move the gearshift lever forward reverse gear, until gear clash can be heard. Depress the clutch pedal slowly.
^ If the gears cease to clash (full disengage at 1 to 1.5 inch from the floor), then hold the pedal at the point of disengagement and increase engine to 4,000 rpm. The clutch should remain disengaged, clutch OK.
^ Any concerns indicated a worn or damaged clutch. Repair as necessary.
4. With the engine idling, move the gearshift lever into fourth gear. Increase the rpm to 2,000 and slowly release the clutch pedal.
^ If the engine stalls, clutch is OK.
^ If the engine does not stall, clutch slipping. Repair as necessary.
5. Compare the clutch evaluation results with the table. The list of conditions are typical faults into which clutch concerns will fall.