Cleaning and Inspection
GENERAL INFORMATIONClean the transmission components in solvent. Then dry the cases, gears, shift mechanism and shafts with compressed air. Dry the bearings with clean, dry shop towels only. Never use compressed air on the bearings. This could damage the bearing rollers.
Replace components that are obviously worn, cracked, chipped or damaged.
Inspect the transmission case. Replace the case if cracked or porous or if any of the bearing and gear bores are damaged.
OUTPUT SHAFT INSPECTION
Measure thickness of the output shaft flange with a micrometer. Minimum allowable flange thickness is 4.70 mm (0.185 inch).
If shaft flange thickness is OK but previously measured second/third gear thrust clearance was incorrect, replace the necessary gear and needle bearing as an assembly.
Check diameter of the first, second and third gear bearing surfaces of the output shaft. Minimum allowable diameters are:
- 38.86 mm (1.629 inch) for first gear surface
- 46.86 mm (1.844 inch) for second gear surface
- 37.86 mm (1.490 inch) for third gear surface
Check output shaft runout with V-blocks and a dial indicator. Maximum allowable runout is 0.06 mm (0.0024 inch).
Replace the output shaft if any surface measured fails to meet stated tolerance.
CLUSTER GEAR INSPECTION
Inspect the cluster gear teeth. Replace the gear if any teeth are worn or damaged or if the bearing surfaces are damaged.
Check diameter of the cluster gear journal with a micrometer. Minimum allowable diameter is 27.860 mm (1.096 inch).
Check condition of the cluster gear front bearing. Replace the bearing if worn, noisy, or damaged.
GEAR-TRAIN AND SYNCHRO
Install the synchro rings on their respective gears. Rotate each ring on the gear and note synchro action. Replace any synchro ring that exhibits a lack of braking action or binds on the gear. Also replace any ring that is worn or has chipped or broken teeth.
Measure end clearance between the synchro ring and the gear with a feeler gauge. Clearance should be 0.06 mm to 1.6 mm (0.024 to 0.063 inch).
Install the needle bearings in the first, second and third gears. Then install the gears on the output shaft and check shaft-to-gear clearance with a dial indicator.
Maximum allowable clearance is 0.16 mm (0.0063 inch). If any gear exhibits excessive clearance, replace the gear and needle bearing.
Check clearance between the shift forks and synchro sleeves with a feeler gauge. Clearance should not exceed 1.0 mm (0.039 inch). Replace the synchro sleeve (and matching hub) if clearance exceeds the stated limit.
Check condition of the reverse idler gear bushing. Replace the gear if the bushing is scored or worn.
GEAR CASE, HOUSING AND INTERMEDIATE PLATE
Clean the case, housing and plate with solvent and dry with compressed air. Replace any component that is cracked, warped or damaged in any way.
Inspect the threads in the case, housing and plate. Minor thread damage can be repaired with steel thread inserts if necessary. However, do not attempt to repair if the cracks are evident around any threaded hole.
Inspect the reverse pin in the adapter/extension housing. Replace the pin if worn or damaged.