For 1990-2009 cars only
- Verify/duplicate the customer concern. If the customer concern can be duplicated, proceed to step 2.
- Perform the following input shaft spin down test.
- Attempt to verify the hard to shift into the gear concern with the engine OFF.
| 2.1. | Set the parking brake and place the vehicle in neutral. |
| 2.2. | Start the engine and allow the vehicle to idle. |
| 2.3. | Gently move the shifter toward the reverse gate and continue to move the shifter until a light grind/rattle can be heard. |
| 2.4. | Once the grind/rattle noise is observed, depress the clutch pedal and note the time required for the grind/rattle noise to stop. Normal spin down time, time required until grinding noise stops, is approximately 3 seconds. |
| • | If the 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 the noise does not stop within 3, inspect the clutch pedal travel and clutch fork travel as described below. |
| - | Clutch Pedal Travel Measurement |
| - | Measure the clutch pedal travel refer to Clutch Hydraulic System Diagnosis . Pedal travel should be between 117-137 mm (4.6-5.4 in). If the clutch pedal travel is not between 117-137 mm (4.6-5.4 in), check for: |
| • | Carpet or floor mat under pedal. |
| • | Faulty bushing/damaged pedal. |
| - | Clutch Fork Travel Measurement |
| - | Measure the clutch fork travel refer to Clutch Hydraulic System Diagnosis . If the clutch fork travel is less than 10.80 mm (0.43 in) check for the following: |
| Important: The first four bullets require master/slave cylinder replacement. |
| • | Fluid leak in hydraulic system |
| • | Damage to the front of the 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 |
| • | If the 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 the blocker and the gear. |
| - | Missing circular spring. |
| - | Worn or damaged shift fork pad/bushing |
| - | Synchronizer sleeve tooth points damaged. |
| • | If the 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. |
