Check whether the fault is accompanied by gearbox noise with the vehicle parked and in neutral.

Check the gearbox/differential oil level

Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY

1. Noise detected from gearbox

2. Oil level not correct

Proceed as instructed

See table S022 GEARBOX NOISE - IN NEUTRAL

2. Restore the correct level and carry out a road test.

Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY

If the fault persists, move on to Step 1

Wash the gearbox thoroughly, spread with talc and carry out a road test.

Check that there are no leaks.

In particular, check the condition of the gaskets:

- gear input shaft seal;

- rear cover gasket;

- differential oil seal

1. Leaks from gaskets

2. Leaks from left differential flange

3. Leaks from right differential oil seal

1. Replace the gaskets

2. Replace the flange

Op. 2110D52 FLANGE ON DIFFERENTIAL - R.R WITH DRIVESHAFT REMOVED

3. Replace the oil seal

Op. 2110D63 RIGHT DIFFERENTIAL SHAFT OIL SEAL - R.R

For 1.9 JTD 8v versions

Use talc to check visually that the gear casing is intact

Replace the gear casing, rear cover or entire gearbox

Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS

For 1.4 16v 1.9 JTD 16v versions

Use talc to check visually that the gear casing is intact

Replace the gear casing, rear cover or entire gearbox

Op. 2110B26 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REASSEMBLE, WASH AND CHECK PARTS - REPLACE SYNCHRONIZERS AND INTERNAL PARTS IF NECESSARY