CLEANING AND INSPECTION
Cleaning
1. Wash all parts, except the bail bearings, in a suitable cleaning solvent.
2. Brush or scrape all foreign matter from the parts. Be careful not to damage any parts with the scraper.
3. Dry all parts with compressed air.
Inspection
1. Inspect the gearbox case for being cracked worn or damaged bearing bores, damaged threads or any other damage which could affect the operation of the gearbox.
2. Inspect the front face of the case for small nicks or burrs that could cause misalignment of the gear-box with the flywheel housing~ Remove all small nicks and burrs with a fine stone.
3. Replace a cover that is bent or distorted. Make sure that the vent hole in the cover is open.
4. Check the condition of the shift levers, forks, shift rails and the levers and shafts.
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5. Examine the ball bearing races for being cracked, worn or rough. Inspect the balls for looseness, wear, end play or other damage. Check the bearings for looseness in the bores. If any of these con-ditions exist, replace the bearings.
6. Replace roller bearings that are broken, worn or rough.
7. Replace the countershaft (cluster) gear, if the teeth are chipped, broken or worn. Replace the counter-shaft If It is bent, scored or worn.
8. Replace the reverse idler gear, or sliding gear if the teeth are chipped, worn or broken. Replace the idler shaft if bent, worn or broken.
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 are properly indexed.
12. Check the blocking rings for the grooves being worn smooth or for the teeth being damaged.’
13. Replace the speedometer drive gear if the teeth are stripped or damaged. Make certain to install the correct size replacement gear.
14. Replace the output shaft if there is any evidence of wear, or if any of the splines are damaged.
15. Inspect the bushing and the seal in the extension housing. Replace them if they are worn or damaged. The bushing and/or seal should be replaced after the extension housing has been installed on the gearbox.
16. Replace the seal in the input shaft bearing retainer.
17. Replace the seals on the cam and shafts.
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