M/T - Rattling Noise On Acceleration
CATEGORYTransmission
SECTION PAGE
4 31
ISSUE CODE
10/95-0619 471
Subject: Correcting a Customer Complaint of a Rattling Noise from the Synchromesh Sleeves
Application: Certain 1994-1995 900 and 9000 Models
with 4-cylinder Engine and Manual Transmission
Customers may complain of a rattling noise during light acceleration and under load at engine speeds of 800-1200 rpm. This noise can be made by the 3rd, 4th, and 5th gear synchromesh sleeves. A new type of spring was introduced into production to remedy this problem after the transmission serial numbers listed below. These springs can be fitted to 1994 and 1995 cars to address a customer complaint.
NOTE:
See also PSI 10/95-0620 for more information on noise from the gearbox.
Cars Affected:
1994-1995 900 models (with 4-cylinder engine and manual transmission) with Transmission Serial No. up to and including J95349
1994-1995 9000 models (with 4-cylinder engine and manual transmission) with Transmission Serial No. up to and including J95478
Parts:
Leaf spring, 3rd, 4th (6 per car) 87 43 791
Leaf spring, 5th (3 per car) 87 43 809
Sleeve 87 34 477
Gasket (for 900 models) 87 34 824
Gasket (for 9000 models) 87 34 832
Nut 87 35 516
Action:
1. Dismantle the gearbox up to and including the input shaft. Refer to Service Manual 4:1, "Manual gearbox," for the model you are working on (pages 471-1 through -6).
2. 3rd/4th Gear: Fit three leaf springs, P/N 87 43 791, between each of the two synchromesh sleeves and the hub (see item 2, Figure 1).
3. 5th Gear: Fit three leaf springs, P/N 87 43 809, between the synchromesh sleeve and hub (see item 3, Figure 2).
4. Hold the synchromesh sleeve and hub together with two rubber bands (see Figure 3) so that the leaf springs do not come loose when the hub is fitted in place.
5. Using a new sleeve (P/N 87 34 477) and nut (P/N 87 35 516), reassemble the gearbox. Refer to Service Manual 4:1, "Manual gearbox," for the model you are working on (pages 471-9 through -19).
Tightening torque, reverse gear shaft support: 28 Nm (20.7 ft. lbs.).
Warranty Information:
To resolve a customer complaint for a vehicle in warranty, submit a claim using the following information: Failure code: 47173-43-5-01-10
Labor operation number: 47171 for 6.8 hr.
Straight time: 0.2 hr. for fifth gear synchromesh sleeve.