Inspection and Verification

Inspection and Verification

CAUTION: If transaxle noise is reported, first check the fluid level. The vehicle should not be driven if the fluid level is low or damage can occur.

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

The technician should have a thorough knowledge of transaxle/clutch operation and accepted general transaxle/clutch guidelines to detect any problems.

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.

Use the following to diagnose and repair a transaxle/clutch concern:

Verify and Document the 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. Do not downshift into 1st when the vehicle is moving faster than 15 mph (25 km/h). This will damage the clutch. For information on recommended shift speeds, refer to the Owner's Literature
- 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 or damage can occur.

An incorrect level may affect the transaxle operation and can result in transaxle damage.

A low fluid level can result in poor transaxle shifting, engagement or damage. It can also indicate a leak in one of the transaxle 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 Pedal Feels Spongy or Has Excessive Travel/Clutch Will Not Disengage
3. With the engine idling, the parking brake on and the clutch pedal up, gently move the gearshift lever forward toward reverse gear, until gear clash can be heard. Depress the clutch pedal slowly.
^ If the gears cease to clash (full disengage at 25.4 to 38.1 mm [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 indicate a worn or damaged clutch. Repair as necessary.
4. With the engine idling, move the gearshift lever into 4th 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 is slipping. Repair as necessary.
5. Compare the road test results with the symptom chart. The chart is a list of conditions that are typical faults into which the clutch will fall. GO to Symptom Chart - Clutch. Symptom Chart - Clutch

Inspect the Gearshift Mechanism

1. Inspect the cables for:
^ signs of damage.
^ broken locks.
^ binding.
^ cables not fully seated or in hold-down brackets.
^ correct routing.
^ correct adjustment.
- If the concern is a gear(s) cannot be selected, jumps out of gear or gear clashes, adjust the cables.
2. Inspect the gearshift for:
^ free play in the gearshift lever (must be no more than 15 mm [0.59 inch]).
- If the gearshift lever free play is too great, check the gearshift cables and repair as necessary.
- If the gearshift lever free play is OK, adjust the gearshift linkage.

Evaluation of the Transaxle

1. During the road test, use the following driving methods to diagnose the problem.
^ Start the engine.
^ Evaluate for excessive or abnormal noise in NEUTRAL while the vehicle is parked.
- Check whether noise is present with the clutch fully disengaged (pedal fully depressed). Check to see if the pedal pulsates abnormally (for clutch diaphragm finger run out).
- Check whether noise is present with the gearshift in the NEUTRAL position and the clutch fully engaged (foot off pedal). With the parking brake engaged, move the gearshift towards the 1st gear position. Apply very slight pressure and note if the gear noise level is reduced. (for gear rollover noise).
- With the clutch fully engaged (foot off pedal), check whether noise is present as the engine speed is raised. If noise reduces, note the engine speed at which this occurs.
^ Listen for any change in noise while depressing and releasing the clutch pedal.
^ Listen for any change in noise while changing the engine rpm.
^ Drive the vehicle and shift through all of the gear ranges, including reverse. Listen for any change in noise in a particular gear.
^ Drive the vehicle in the gear in which the noise is most noticeable. Depress the clutch pedal and leave the gear engaged. Listen for any change in noise.
^ Drive the vehicle in the gear in which the noise is most noticeable. Depress the clutch pedal and shift the transmission into NEUTRAL. Release the clutch pedal and allow the vehicle to coast.
2. Compare the road test results with the symptom charts. The charts are a list of conditions that are typical faults into which the transaxle will fall. GO to Symptom Chart - Clutch, GO to Symptom Chart - Transaxle or GO to Symptom Chart - Noise, Vibration and Harshness (NVH). Symptom Chart - Clutch Symptom Chart - Transaxle Symptom Chart - Noise, Vibration and Harshness (NVH)