| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
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| Check whether the fault is accompanied by gearbox noise with the vehicle parked and in neutral.Check the gearbox/differential oil level Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY | Move on to Step 1 | 1. Noise detected from gearbox2. Oil level not correct | Proceed as instructed See table S022 GEARBOX NOISE - IN NEUTRAL2. Restore the correct level and carry out a road test. Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY If the fault persists, move on to Step 1 |
| 1 | CHECK FOR LEAKS | All OK | Problems encountered | Operation |
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| Wash the gearbox thoroughly, spread with talc and carry out a road test.Check that there are no leaks.In particular, check the condition of the gaskets:- gear input shaft seal;- rear cover gasket;- differential oil seal | Move on to Step 2 | 1. Leaks from gaskets2. Leaks from left differential flange3. Leaks from right differential oil seal | 1. Replace the gaskets2. Replace the flange Op. 2110D52 FLANGE ON DIFFERENTIAL - R.R WITH DRIVESHAFT REMOVED 3. Replace the oil seal Op. 2110D63 RIGHT DIFFERENTIAL SHAFT OIL SEAL - R.R |
| 2 | GEAR CASING CHECK | All OK | Problems encountered | Operation |
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| For 1.9 JTD 8v versionsUse talc to check visually that the gear casing is intact | End of diagnosis | Casing damaged, with presence of cracks or deformities | Replace the gear casing, rear cover or entire gearbox Op. 2110B32 MANUAL GEARBOX (5 SPEED) WITH DIFFERENTIAL - DISMANTLING AND REASSEMBLY - WASH AND CHECK PARTS - REPLACE SYNCHRONISERS, INNER CONTROLS, GEARS, SHAFTS AND BEARINGS |
| 2 | GEAR CASING CHECK | All OK | Problems encountered | Operation |
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| For 1.4 16v 1.9 JTD 16v versionsUse talc to check visually that the gear casing is intact | End of diagnosis | Casing damaged, with presence of cracks or deformities | Replace the gear casing, rear cover or entire gearbox Op. 2110B26 MANUAL GEARBOX (6 SPEED) WITH DIFFERENTIAL - DISMANTLE AND REASSEMBLE, WASH AND CHECK PARTS - REPLACE SYNCHRONIZERS AND INTERNAL PARTS IF NECESSARY |
