Cleaning and Inspection

1. Clean the following components:
- The bearings
Remove all of the old lubricant and any dirt.
- The shafts
- The sprockets
- The chain
- The oil feed ports and channels in each case half
Apply compressed air to each oil feed port and channel in order to remove any obstructions or cleaning solvent residue.
- All of the mating and sealing surfaces.

2. Inspect the bearings and the thrust washers for the following conditions:
- Spalling
- Brinelling
- Corrosion

3. Inspect the gear teeth for the following conditions:
- Excessive wear or damage
- Spalling
- Cracks
- Corrosion

4. Inspect the gear splines for the following conditions:
- Excessive wear
- Spalling
- Cracks
- Twist
- Corrosion

5. Inspect the shaft splines for the following conditions:
- Excessive wear
- Spalling
- Cracks
- Distortion
- Corrosion

6. Inspect the retainer rings for the following conditions:
- Excessive wear
- Distortion
- Damage

7. Inspect the case halves for the following conditions:
- Damaged or warped mating surfaces
- Cracks
- Porosity
- Damaged thread holes

8. Inspect the synchronizer stop rings for the following conditions:
- Cracks
- Chips
- Spalling
- Excessive wear

9. Inspect the synchronizer hub and the sleeve for the following conditions:
- Cracks
- Chips
- Spalling
- Excessive wear

10. Inspect the pads on the mode fork and on the range fork for the following conditions:
- Wear
- Distortion

11. Inspect the oil pump gears and the case halves for the following conditions: - Spalling
- Cracks
- Damage
- Wear
Replace the complete assembly if there is wear.

12. Inspect the following components for excessive wear:
- The input gear
- The planetary carrier
- The range shift hub tooth chamfers