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Vauxhall Workshop Service and Repair Manuals

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Astra J

Symptoms - Manual Transmission



Complaint/Condition
Possible Cause
correction

Knock at Low Speeds
•  Worn drive axle joint
•  Worn side gear or pinion gear bores


•  Inspect drive axle joint and replace if necessary.
•  Inspect differential case and replace if necessary.


Noisy Around Turns
Worn differential gears
Inspect differential gears and replace if necessary.

Clunk or Acceleration or Deceleration
•  Loose engine mounts
•  Worn inboard drive axle joint
•  Worn differential pinion shaft
•  Worn side gear hub counterbore


•  Inspect engine mounts and tighten if necessary.
•  Inspect inboard drive axle joint and replace if necessary.
•  Inspect differential pinion shaft and replace if necessary.
•  Inspect side gear hub counterbore and replace if necessary.


Click Noise On Turns
Worn outboard drive axle C/V joint
Inspect C/V joint and replace if necessary.

Noisy in Neutral With Engine Running
•  Worn input gear bearing
•  Worn speed gear bearing
•  Worn bearing races


•  lnspect bearing and replace if necessary.
•  lnspect bearing and replace if necessary.
•  lnspect bearing race and replace if necessary.


Noisy in First Gear Only
•  Worn, chipped, or scored 1st speed constant-mesh gears
•  Worn, shipped, or scored 1st/2nd synchronizer


•  lnspect gears and replace if necessary.
•  lnspect synchronizer and replace if necessary.


Noisy in Second Gear Only
•  Worn, chipped, or scored 2nd speed constant-mesh gears
•  Worn, chipped, or scored 1st/2nd synchronizer


•  lnspect gears and replace if necessary.
•  lnspect synchronizer and replace if necessary.


Noisy in Third Gear Only
•  Worn, chipped, or scored 3rd speed constant-mesh gears
•  Worn, chipped, or scored 3rd/4th synchronizer


•  lnspect gears and replace if necessary.
•  lnspect synchronizer and replace if necessary.


Noisy in Fourth Gear Only
•  Worn, chipped, or scored 4th speed constant-mesh gears
•  Worn, chipped, or scored 3rd/4th synchronizer
•  Worn, chipped, or scored output gear
•  Worn, chipped, or scored output gear


•  lnspect gears and replace if necessary.
•  lnspect synchronizer and replace if necessary.
•  lnspect gear and replace if necessary.
•  lnspect gear and replace if necessary.


Noisy in Fifth Gear Only
•  Worn, chipped, or scored 5th speed constant-mesh gears
•  Worn, chipped, or scored 5th synchronizer
•  Worn, chipped, or scored output gear


•  lnspect gears and replace if necessary.
•  lnspect synchronizer and replace if necessary.
•  lnspect gear and replace if necessary.


Noisy in Reverse Only
•  Worn, chipped, or scored reverse speed constant-mesh gears
•  Worn or damaged output gear


•  lnspect gear and replace if necessary.
•  lnspect gear and replace if necessary.


Noisy in All Gears
•  Fluid level low
•  Worn or damaged wheel bearings
•  Worn, chipped, or scored input/output shaft gear
•  Worn output gear bearing
•  Loose shift rail guide bolt
•  Worn, chipped, or scored 1st, 2nd, 3rd, 4rd, 5th, or Reverse gears.


•  Add fluid to proper level.
•  Inspect wheel bearing and replace if necessary.
•  Inspect gear and replace if necessary.
•  Inspect output gear bearing and replace if necessary.
•  Tighten shift rail guide bolt.
•  Inspect components and replace as necessary.


Slips Out of Gear
•  Loose transaxle mounts
•  Bent or worn cables
•  Broken or loose input gear bearing retainer
•  Worn or bent shift fork
•  Dirty clutch housing and engine
•  Stiff shift lever seal
•  Manual transaxle internal shift mechanism malfunction


•  Tighten or replace mounts.
•  Inspect cables and replace if necessary.
•  Inspect shift fork and replace if necessary.
•  Inspect shift fork and replace if necessary.
•  Clean clutch housing and engine.
•  Inspect seal and replace if necessary.
•  Disassemble transaxle, repair as necessary.


Slips Out of Gear While Accelerating
•  Missing or misadjusted first gear thrust bearing or washer
•  Worn or damaged fist gear spline lock on 1st/2nd synchronizer
•  Worn of damaged second gear spline lock on 1st/2nd synchronizer
•  Worn or damaged third gear spline lock on 3rd/4th synchronizer
•  Worn or damaged fourth gear spline lock on 3rd/4th synchronizer
•  Worn or damaged 5th gear spline lock on the 5th/Reverse synchronizer
•  Worn or damaged Reverse gear spline lock on the 5th/Reverse synchronizer
•  Worn or damaged 1st, 2nd, 3rd, 4th, 5th or reverse gear spline lock
•  Manual transaxle internal shift mechanism malfunction


•  Inspect bearing and washer and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Inspect spline lock and replace if necessary.
•  Disassemble transaxle, repair as necessary.


Slips Out of Gear While Coasting
•  Damaged, worn, or missing shift rails
•  Manual transaxle internal shift mechanism malfunction


•  Inspect shift rails and replace if necessary.
•  Disassemble transaxle, repair as necessary.


Fluid Leakage
•  Fluid level high
•  Damaged axle shaft seals
•  Vent cap plugged
•  Poor sealing on shift cover
•  Poor sealing between case and clutch housing
•  Poor sealing on rear cover
•  Poor sealing or loose back-up lamp switch
•  Poor sealing or loose vehicle speed sensor


•  Drain excess fluid.
•  Inspect axle shaft seals and replace if necessary.
•  Clear or replace vent cap.
•  Replace sealer on shift cover.
•  Replace sealer between case and clutch housing and tighten.
•  Replace sealant on rear cover and tighten.
•  Tighten switch or replace sealant as needed.
•  Tighten sensor or replace sealant as needed.

 

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