TR6060 Manual Transmission - Inspection

INSPECTION






NOTE: Minor corrosion, nicks, or pitting can be smoothed with 400 grit emery and polished out with crocus cloth.

Mainshaft: Inspect bearing surfaces (1) for wear or flat-spots. Inspect splines (2) and snap ring grooves for wear. Inspect output seal surface for wear.





Countershaft: Inspect roller bearings (1) for wear, peeling, pitting or flat-spots. Inspect bearing surfaces (2) for wear or flat-spots. Inspect gear teeth (3) for worn, chips or cracks. Inspect splines and snap ring grooves for wear.





Input Shaft: Inspect input shaft bearing (1) for wear, peeling, pitting or flat-spots. Inspect input shaft splines (2) for wear. Inspect forth gear (3) for worn, chipped, or cracked teeth. Inspect input seal surface for wear.





Gears: Inspect gears (1) for worn, chips or cracked teeth and bearing surfaces for wear, peeling, pitting or flat-spots. Inspect gear bearings (2) for wear, peeling, pitting, flat-spots or damaged bearing cage.





Synchronizer components: Inspect synchronizer rings (1) for worn, chips, or cracked teeth and burned or flaking friction material. Place blocker rings on gears. While applying pressure and rotating the blocker ring measure the clearance between the blocker ring and gear. If the clearance is less than 0.75 mm (0.030 in.) replace blocker ring. Synchronizer rings are serviced as an assembly.





Inspect synchronizer sleeve (1) and hub (2) for worn teeth. Inspect synchronizer detents (3) for broken springs, missing balls or cracked/damaged housings.





Shift Forks/Shift Rails: Inspect shift forks (1) for distortion. Inspect fork shoes (2) for wear or cracks. Fit shoes in synchronizer sleeve to ensure parts fit and work smoothly. Inspect shift rails for wear. Inspect shift rail bushings and bearings for wear.