Manual Transaxle Hard to Shift Into Gear

MANUAL TRANSAXLE HARD TO SHIFT INTO GEAR
1. Verify/duplicate customer concern. If customer concern can be duplicated, proceed to step 2.
2. Perform the following input shaft spin down test.
2.1 Set parking brake and place vehicle in neutral.
2.2 Start engine and allow vehicle to idle.
2.3 Gently move shifter toward reverse gate and continue to move shifter until a light grind/rattle can be heard.
2.4 Once grind/rattle noise is observed, depress clutch pedal and note the time required for grind/rattle noise to stop. Normal spin down time (time required until grinding noise stops) is approximately 3 seconds.
^ If noise stops (input shaft stops spinning) within approximately 3 seconds, the clutch disc/pressure plate and clutch hydraulic system are not the cause of the hard to shift into gear or grind into gear concern. Proceed to step 3.
^ If noise does not stop within 3 seconds, inspect clutch pedal travel and clutch fork travel as described below.

Clutch Pedal Travel Measurement:
Measure clutch pedal travel according to the "Clutch Hydraulic System Diagnosis" (under Clutch; Testing and Inspection). Pedal travel should be between 117 - 137 mm (4.6 - 5.4 inch). If clutch pedal travel is not between 117 - 137 mm (4.6 - 5.4 inch), check for:
- Carpet or floor mat under pedal.
- Faulty bushing/damaged pedal.

Clutch Fork Travel Measurement:
Measure clutch fork travel according to the "Clutch Hydraulic System Diagnosis" (under Clutch; Testing and Inspection). If clutch fork travel is less than 10.80 mm (0.43 inch) check for the following:

IMPORTANT: The first four bullets require master/slave cylinder replacement.
- Fluid leak in hydraulic system.
- Damage to front of dash.
- Air in system.
- Damaged master/slave cylinder.
- Master/slave cylinder improperly installed.

If pedal travel and fork travel are ok and clutch hydraulics are functioning properly, check for:
- Bent fork.
- Damaged pressure plate and/or clutch disc.

3. Attempt to verify the hard to shift into gear concern with the engine Off.
- If concern is not observed with the engine Off, check for:
- Damaged blocker ring, blocker ring teeth rounded off.
- Burnt blocker ring/blocker ring friction material debonded.
- Oversized blocker ring (can check with feeler gage for clearance between blocker and gear).
- Missing circular spring.
- Worn or damaged shift fork pad/bushing.
- Synchronizer sleeve tooth points damaged.
- If concern is observed with the engine off, check for:
- Shift cable retainer clip loose/missing.
- Damaged/kinked shift cable.
- Damaged shift tower components.
- Shifter assembly damaged/broken.