Cleaning and Inspection

GENERAL INFORMATION
Clean the transmission components in solvent. 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 cause severe damage to the bearing roller and race surfaces.
If output shaft flange thickness is within specification but any gear thrust clearance is out of specification, replace the necessary gear and gear needle bearing as an assembly.

GEAR CASE, ADAPTER/EXTENSION HOUSING, INTERMEDIATE PLATE
Clean the case, housing, and intermediate plate with solvent and dry with compressed air. Replace the case if cracked, porous, or if any of the bearing and gear bores are damaged.
Inspect the threads in the case, housing, arid plate. Minor thread damage can be repaired with steel thread inserts, if necessary. Do not attempt to repair any threads which show evidence of cracks around the threaded hole.

OUTPUT SHAFT
Check thickness of the output shaft flange with a micrometer or vernier calipers. Minimum allowable flange thickness is 4.70 mm (0. 1850 inch).
Check diameter of the first, second, arid third gear bearing surfaces on the output shaft. Minimum diameters are as follows:
- First gear bearing surface is 38.86 min (1.529 inch).
- Second gear bearing surface is 46.86 min (1.844 inch).
- Third gear bearing surface is 37.86 min (1.490 inch).

Check Output Shaft Tolerances:

Measure output shaft runout with a dial indicator and V-blocks. Runout should not exceed 0.06 mm (0.0024 inch).
Replace output shaft if measurement of any surface is out of specification. Do not attempt to repair out of specification components.

COUNTERSHAFT
Inspect the countershaft gear teeth. Replace the countershaft if any teeth are worn or damaged. Inspect the bearing surfaces and replace shaft if any surface shows damage or wear.
Check condition of the countershaft front bearing. Replace the bearing if worn, noisy, or damaged.

GEAR AND SYNCHRONIZER

Check Gear-To-Shaft Oil Clearance:

Install the needle bearings in the first, second, third and counter fifth gears. Install the gears on the output shaft. Then check oil clearance between the gears and shaft with a dial indicator. Oil clearance for all three gears is 0.16 mm (0.0063 inch) maximum.

Check Synchronizer Ring Wear:

Check synchronizer ring wear. Insert each ring in matching gear. Measure clearance between each ring and gear with feeler gauge. Clearance should be 0.06 - 1.6 mm (0.024 - 0.063 inch).

Check Fork-To-Hub Clearance:

Check shift fork-to-synchronizer hub clearance with a feeler gauge. Replace the fork if clearance exceeds 1.0 mm (0.039 inch).

Reverse Idler Gear Bushing:

Check the condition of the reverse idler gear bushing. Replace the gear if the bushing is damaged or worn.