Inspection and Repair

1. Clean all parts with solvent and dry them with compressed air.





2. Inspect these parts for cracks and damaged sealing surfaces:
- Case
- Extension housing
- Shift cover
- Input bearing retainer
- Counter shaft rear bearing retainer
Use a fine mill file to dress minor scratches or burrs. Replace severely damaged parts. Replace the counter shaft rear bearing retainer if the tangs are broken.





3. Look at surfaces on the above parts which support bearings and shafts. Replace parts which have excessive wear in these areas. Do not replace gears if phosphate coatings are worn.
4. Examine the bearing surfaces of the following parts:
- Input shaft
- Mainshaft and its gears








- Counter shaft and the fifth drive gear
- Reverse idler shaft and its gear.
Replace parts which show signs of excessive wear. Do not file surfaces which have been hardened and precision ground.
5. Inspect shift mechanism parts as follows:
a. Look for wear on the shift shaft.





b. Look at the detent/guide plate and offset lever, for worn edges or grooves where the detent ball and lug travel.
c. Look for worn edges on these parts:
^ Selector arm
^ Interlock plate





^ Selector plates for the 1-2 and 3-4 shift forks.





^ 5-R shift lever and the rollers on the reverse fork and the 5th shift rail/fork.
d. Look for worn mating surfaces on the following parts:





^ 1-2 shift fork, pads and synchronizer sleeve.
^ 3-4 shift fork, pads and synchronizer sleeve
^ 5th shift rail/fork, pads and synchronizer sleeve
^ Reverse fork and the mating sleeve surface of the reverse idler gear.
6. Inspect the following bearings for excessive wear, as follows:
a. Crankshaft pilot bushing for the front of the input shaft
^ Clutch release bearing
^ Input shaft bearing
^ Mainshaft pilot bearing rollers





^ Mainshaft thrust bearing and its mating surfaces.
^ Speed gear roller bearing on the mainshaft





^ Mainshaft rear bearing
^ Counter shaft front and rear bearings
Replace any bearing and its races that show roughness.








7. Inspect the gear tooth surfaces on all the gear sets. Replace all mating gears in a set if any one has excessive wear on the meshing surfaces of its teeth. Look for fractures, pitting, scoring and spelling.
8. Disassemble the three synchronizer assemblies, as follows:





a. The 1-2, which has three-piece assemblies.





b. The 3-4, which has sintered metal blocking rings.





c. The 5-R, which uses single-piece brass blocking rings.





d. Examine the fit between the hub and sleeve of each synchronizer. Besides binding shift linkage, an excessively tight or loose hub-to-sleeve fit will cause what is known as a "hard shift.





f. Measure the clearance between the blocking ring and the speed gear.
Excessive wear on either the blocking ring or the speed gear cone surface will cause "shift block-out" or "gear clash."
Blocking ring to gear clearance:
Standard:
1-2 Gear: 0.87 - 1.4 mm (0.032 - 0.056 inch).
3-4 Gear: 0.88 - 1.5 mm (0.035 - 0.059 inch).





g. Look for evidence of gear clash on both the synchronizer sleeve teeth or the clutch teeth on the speed gear.





h. Finally, look at the synchronizer sleeve and speed gear clutch tooth area for cause of.