Inspection

MAINSHAFT AND SYNCHRONIZERS
1. Clean all the parts in a suitable solvent. Air dry all the parts.

Important: Do not spin the bearings without a lubricant.

2. Lubricate the mainshaft bearings with the proper transmission lubricant. Refer to Lubrication Specifications.
3. Check the bearings for rough rotation.
4. Inspect the mainshaft gears for the following conditions:
- Cracks
- Nicks
- Chipped gear teeth
- High spots (small-shiny spots on the gear teeth mating surface) that could cause gear noise

5. Inspect related gear surfaces like thrust faces and bearing surface diameters.
6. Inspect the synchronizer sleeves for a sliding fit on the synchronizer hubs. The synchronizer hubs must have a force fit on the mainshaft splines.
7. Replace a synchronizer hub that does not require a force fit on the mainshaft splines.
8. Inspect the synchronizer springs and the keys for damage.
9. Inspect the synchronizer rings for excess wear.
10. Inspect the synchronizer clutching teeth for the following conditions:
- Scuffs
- Nicks
- Burrs
- Damage

11. Inspect the mainshaft drive gear clutching cones for synchronizer ring metal transfer.
12. Inspect all the gear teeth for excess wear.
13. Remove nicks and burrs with a soft stone or a crocus cloth.
14. Replace any components that are bent or show signs of excessive wear. Inspect the mating parts.
15. Inspect the bearings and the bearing surfaces for the following conditions:
- Nicks
- Burrs
- Bent cages
- Wear
- Overheating
- Scoring
- Pitted condition
- Countershaft

COUNTERSHAFT
1. Clean the countershaft in a suitable solvent. Air dry the countershaft.

Important: Do not disassemble the countershaft. Individual components of the countershaft are not serviced. A damaged or worn countershaft must be replaced as a complete assembly.

2. Inspect the countershaft for cracks.
3. Replace a cracked countershaft.
3. Inspect the countershaft gears for the following conditions:
- Scuffed gear teeth
- Nicked gear teeth
- Burred gear teeth
- Broken gear teeth

4. High spots (Small shiny spots on the gear teeth mating surfaces) that could cause gear noise
5. Lubricate the countershaft bearings with the proper transmission lubricant. Refer to Lubrication Specifications.
6. Replace the bearing assembly if any of the following conditions exist:
- Roughness of rotation
- Burrs
- Pitted condition

7. Replace the bearing race and inspect the mating parts If the following conditions exist:
- Scoring
- Wear
- Discoloration from overheating

FRONT AND REAR HOUSINGS
1. Clean the transmission housing in a suitable solvent. Air dry the housing.
2. Inspect the countershaft bearing race bore for the following conditions:
- Wear
- Scratches
- Grooves

3. Replace the housing if the countershaft bearing race bore is worn or damaged.
4. Inspect the housing for the following conditions:
- Cracks
- Damaged threads
- Nicked mounting surfaces
- Burrs
- Scratches

5. Replace a cracked housing.
6. Clean up damaged threads with the correct size tap.
7. Replace the housing if scratches, grooves or scoring cannot be removed with a soft stone or
8. Inspect the machined mating surfaces for flatness. Check the mating surfaces with a straight edge.

SHIFT SHAFT AND SHIFT FORKS
- Clean all the parts in a suitable solvent. Air dry the parts.
- Inspect the shift shaft for wear or scoring.
- Inspect the shift shaft forks for wear, scoring, or distortion.
- Inspect the roll pins for wear or distortion.
- Inspect the shift shaft socket assembly components for wear or distortion.
- Replace the worn or distorted parts. Inspect all the mating parts.