Cleaning and Inspection
CLEANING1. CAUTION: Do not clean, wash or soak transmission seals in cleaning solvents or transmission seals could be damaged. Dry all parts with compressed air.
Wash all parts except ball bearings, 0-rings and seals in a suitable cleaning solvent. Brush or scrape all foreign matter from the parts. Be careful not to damage any parts with the scraper.
2. Clean the magnet in the bottom of the case with kerosene or mineral spirits.
INSPECTION
1. Inspect transmission case for cracks, worn or damaged bearing bores, damaged threads or any other damage that could affect operation of the transmission.
2. Replace any cover that is bent or distorted.
3. Check the condition of the shift levers, forks, shift rails, and the lever and shafts.
4. Inspect the ball bearings.
5. Replace roller bearings that are broken, worn or rough, and check their respective races.
6. Replace the countershaft cluster gear if the teeth are chipped, broken or worn. Replace the countershaft cluster gear if it is bent, scored or worn.
7. Replace the reverse idler gear if the teeth are chipped, worn or broken. Replace the reverse idler gear shaft if bent, worn or scored.
8. Replace the input shaft and gear if the splines are damaged or if the teeth are chipped, worn or broken.
9. Replace all other gears that are chipped, broken or worn.
10. Check the synchronizer sleeves for free movement on their hubs. Make sure the alignment marks (if present) are properly indexed.
11. Inspect the synchronizer blocking rings for widened index slots, rounded clutch teeth and smooth internal surfaces (must have machined grooves). With the synchronizer blocking ring on the bearing cone and roller, the distance between the face of the synchronizer blocking ring and the clutch teeth on the first and second gear must not be less than 0.9 mm (0.035 inch) and for third, fourth, fifth and reverse not less than 0.6 mm (0.025 inch).
12. Replace speedometer drive gear if teeth are stripped or damaged. Make certain to install correct size replacement speedometer drive gear
13. Replace the output shaft if there is any evidence of wear or if any of the splines are damaged.
14. Inspect extension housing bushing and oil seal in the extension housing, and replace if worn or damaged. The oil seal should be replaced after the extension housing has been installed on the transmission.