Pleasurecraft Marine Pleasurecraft 302/2A Owner's Manual - Warner Gear
WARNER GEAR
TROUBLE SHOOTING
CHART
REMEDY
KEY TO TROUBLESHOOTING CHART
COMPLAINTS &
SYMPTOMS
Transmission in Boat
Transmission Removed
INTERNAL & EXTERNAL LEAKS
1. Oil leaks at pump
1 2 3 8
2. Oil on exterior of
trans.
1 4 6 7
2 5 8
3. Oil leaks at rear
bearing retainer
1 2 3 8
4. Water in
transmission oil or
oil in cooling water
9
5. Leaks at coupling
31 44
6. Oil leaks out
breather
15 19 22 40 45
17 23
TRANSMISSION MALFUNCTIONS IN ALL RANGES
1. No oil pressure
10
11 12
2. Low oil pressure
13 15 16 18
17
3. High oil temperature
9 15 19 20 21 22
42
4. Failure of V-Drive
gear
14 42 43
TRANSMISSION MALFUNCTIONS IN FORWARD RANGE
1. Low oil pressure
13 15 16 18
17
2. Forward clutch
engages improperly
37
12 23 24 25 26 27 28
3. Forward clutch drags
37
26 27 28
TRANSMISSION MALFUNCTIONS IN REVERSE RANGE
1. Low oil pressure
13 15 16 18
17
2. Reverse clutch
engages improperly
37
24 25 25 29
3. Reverse clutch drags
37
26 28 29
4. Reverse gear set
failure
43 42
TRANSMISSION MALFUNCTIONS IN NEUTRAL
1. Output shaft drags
excessively in
forward rotation
37
26 27 28
2. Output shaft drags
excessively in
reverse rotation
37
26 28 29 42
MISCELLANEOUS TRANSMISSION PROBLEMS
1. Regulator valve buzz
30
2. Gear noise-forward
31
14 32
3. Gear noise-reverse
31
14 32 42
4. Pump noise
15
17 32
5. Damper noise or
failure
33 34 35 36
6. Shifts hard
16 39
7 37 38
7. High oil pressures
16 40 41
*If installation allows access, otherwise remove transmission
1.
Loose bolts -tighten
2. Damaged
gasket
3.
Damaged oil seal
4.
Oil line fittings loose - tighten
5.
Case leaks, porosity - replace
6.
Oil filler plug or cap leaks-replace or tighten
7.
Damaged control valve "O" ring
8.
Foreign material on mating surfaces – clean
9.
Damaged oil cooler, water and oil mixing - replace
10. No oil - check at once
11. Pump improperly located for engine rotation - locate
correctly
12. Sheared drive key - replace
13. Faulty oil gauge - clean or replace, bleed air from
gauge line
14. Bearing preload not properly adjusted
15. Low oil level - add oil to proper level
16. Regulator valve stuck - clean surfaces of burrs, dirt,
or scoring. Polish inner bore with crocus cloth until
valve moves freely
17. Worn oil pump - replace if necessary
18. Regulator spring weight low-replace
19. High oil level – drain oil to proper level
20. Low water level in cooling system
21. Dirty oil cooler- clean or replace
22. Cooler too small - replace with large cooler
23. Worn or misaligned bushing in transmission case -
replace
24. Worn or damaged clutch piston oil seals
25. Worn or damaged clutch sealing rings
26. Clutch improperly assembled
27. Damaged or broken belleville spring
28. Worn or damaged clutch plate(s) - replace
29. Damaged or broken clutch springs
30. Regulator valve sticking
31. Inadequate torque on output shaft nut - tighten
32. Nicks on gears - remove with stone
33. Excessive runout between engine housing and
crankshaft
34. Wrong damper assembly
35. Damaged damper assembly parts - replace
36. Body - fit bolts not used in mounting holes
37. Control linkage improperly adjusted
38. Control lever and poppet ball corroded - clean and
lubricate
39. Control linkage interference - check
40. Wrong oil used in transmission - change
41. Cold
oil
42. Planetary gear failure- replace or repair
43. Transmission operating in reverse when boat moves
forward - selector must always be located over the
"F" on side of case when boat is driven forward
44. Apply Permatex under coupling nut
45. External plumbing for cooler improperly connected
30