Initial Inspection and Diagnostic Overview

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. Inspect the front face of the case for small nicks or burrs that could cause misalignment of the transmission with the flywheel housing. Remove all small nicks or burrs with a fine file.
3. Replace any cover that is bent or distorted.
4. Check the condition of the shift levers, forks, shift rails, and the lever and shafts.
5. Inspect the ball bearings. Refer to Bearing Inspection.
6. Replace roller bearings that are broken, worn or rough and check their respective races.
7. 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.
8. Replace the reverse idler gear and bushing or sliding gear if the teeth are chipped, worn or broken. Replace the reverse idler gear shaft if bent, worn or scored.
9. Replace the input shaft and gear if the splines are damaged or if the teeth are chipped, worn or broken. If the roller bearing surface in the bore of the gear is worn or rough, or if the cone surface is damaged, replace the gear and the gear rollers.
10. Replace all other gears that are chipped, broken or worn.
11. Check the synchronizer sleeves for free movement on their hubs. Make sure that the alignment marks (if present) are properly indexed.





12. 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 gear must not be less than 0.5 mm (0.020 inch).
13. Replace speedometer drive gear if teeth are stripped or damaged. Make certain to install correct size replacement speedometer drive gear.
14. Replace the output and fifth gear drive shaft if there is any evidence of wear or if any of the splines are damaged.
15. Inspect extension housing bushing and oil seal in the extension housing and replace if worn or damaged. The extension housing bushing or oil seal should be replaced after the extension housing has been installed on the transmission.
16. Replace the oil seal.