Monday, Dec 21, 2015 at 22:12
The vibration coming in when the clutch is released, shows the likely source as the gearbox input shaft (or clutch shaft, as it's sometimes called).
The greatest single source of problems and failures in Japanese gearboxes, is in the needle roller bearing that fits in the end of the input shaft, inside the gearbox.
The mainshaft fits into the input shaft here, and is supported by that needle roller bearing.
That needle roller bearing in most Japanese gearboxes is light duty - it operates with close tolerances, as far as needles-to-shaft clearances go - and it's generally the first bearing in the gearbox to fail.
When they start to fail, the mainshaft starts to jump around inside the gearbox, creating vibration - as the front end of the mainshaft is no longer held in position very securely.
The next thing that happens is the needle rollers start to break up and then they fall out and get mixed up with rotating teeth on the gears - and they get mixed up with the rotating balls and rollers in the other bearings.
By that stage, the gearbox is making LOTS of grinding and crunching and grating noises - and it's not long before you have total gearbox failure.
You can cheack on gearbox condition fairly easily by draining off a little gearbox oil when its cold.
Oil with a "silver paint look" is not a good sign and indicates failure is not far off, as there are many metal particles being shed.
Oil with tiny chunks of metal in it, shows that bearings have already started to fail in a big way, and that gearbox failure is going to happen, VERY shortly.
You can buy drain plugs that have a magnet built into them - these are very useful as an indicator of gearbox and diff condition.
Oil should basically be pretty clean and only slightly discoloured.
Badly discoloured oil, accompanied by a pungent burnt smell, indicates the oil has been running at too high a temperature, due to insufficient oil, or overloading coupled with high ambient temperatures - and this will harden seals and produce oil leaks.
Cheers, Ron.
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