Manual Transaxle Hard Into Gear

1. Verify/duplicate the customer's concern.
2. If the customer's concern can be duplicated, proceed to the next step.
3. Perform the input shaft spin down test.
To test for proper input shaft spin down, perform the following test:
a. Set parking brake and place vehicle in neutral and allow vehicle to idle.
b. Gently move shifter toward reverse gate and continue to move shifter until a light/grind rattle can be heard.
c. Once grind/rattle noise is observed, depress clutch pedal and note the time required for grind/rattle noise to cease.
d. Normal spin down times (time required until grinding noise ceases) are approximately 3 seconds.
4. If noise ceases (shaft stops spinning) within 3 seconds, proceed to next step. If noise does not cease within 3 seconds inspect clutch fork travel and clutch pedal travel.
Pedal Travel Measurement:
Measure clutch pedal travel according to the "Clutch Master and Actuator Cylinder Assembly Diagnosis". Pedal travel should be between 117 mm - 137 mm (4.6 - 5.4 inch). If pedal travel is not between 117 mm and 137 mm, check for:
- Carpet or floor mat under pedal.
- Faulty bushing/damaged pedal.
Fork Travel Measurement:
Measure fork travel according to the "Clutch Master and Actuator Cylinder Assembly Diagnosis". If fork travel is less than 10.80 mm (0.43 inch) check for the following:

IMPORTANT: The first three 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.
5. If spin down times are approximately 3 seconds, the clutch disc/pressure plate and clutch hydraulic are not the cause of hard into gear or grind into gear complaint. Proceed to the next step.
6. Attempt to verify the concern with the engine Off. If the complaint is not observed with the engine Off, proceed to the next step. If the complaint is observed with the engine off, inspect for the following:
- Shift cable retainer clip loose/missing.
- Damaged/kinked shift cable.
- Damaged shift tower components.
- Shifter assembly damaged/broken.
7. If the complaint is not observed with the engine Off, inspect for the following:
- Damaged blocker ring, blocker ring teeth rounded off.
- Burnt blocker ring/blocker ring friction material debonded.
- Debonded blocker ring friction material.
- Oversized blocker ring (can check with feeler gage for clearance between blocker and gear).
- Missing circular spring.
- Worn damaged shift fork pad/bushing.
- Synchronizer sleeve tooth points damaged.