Inspection

1. Inspect gears for worn or damaged synchronizer cone, hub sleeve coupling, gear teeth and inner and end surfaces.
2. Inspect input shaft gear assembly as follows:
a. Clearance between 3rd and 2nd gears is 0.0020-0.0099 inch.
b. Clearance between 4th gear and bearing cone is 0.0064-0.0163 inch.
3. Inspect input shaft for worn teeth, then check run-out by mounting in a lathe or V-blocks. Maximum allowable run-out is 0.002 inch.
4. Inspect mainshaft gear assembly as follows:
a. Clearance between 1st and differential drive gear is 0.002-0.019 inch.
b. Clearance between 2nd gear and main 3rd gear is 0.0069-0.0199 inch.
5. Inspect mainshaft for the following conditions:
a. Worn or damaged gear contact surfaces, splines or gear teeth.
b. Clogged oil passage.

Measuring Main Shaft Gear Run-out:

c. Mainshaft gear runout. Mount gear shaft in a lathe or V-blocks and measure run-out at point shown in example. Maximum allowable runout is 0.0006 inch.
d. Measure clearance between mainshaft and gears where the gear is installed. Measure inside diameter of gear. Difference between two measurements is clearance. If clearance is more than 0.003 inch, replace gear and/or shaft as necessary.
6. Inspects synchronizer ring for following conditions:
a. Engagement with ring. Ring must engage smoothly with gear.
b. Worn or damaged teeth or tapered surface.
c. Clearance from side of gear. Press synchronizer ring uniformly against gear and measure around circumference. Standard clearance is 0.059 inch.
7. Inspect clutch hub for worn or damaged splines, synchronizer key groove or end surface. Check for a smooth hub sleeve when it is installed.
8. Inspect clutch hub sleeve for worn or damaged hub splines of sleeve fork groove.
9. Inspect synchronizer keys and springs for worn key and bent springs.
10. Inspect differential for damaged or worn gears and cracked or damaged gear case.
11. Inspect speedometer drive gear assembly for worn or damaged teeth or O-ring and seal.
12. Inspect reverse idler gear for worn or damaged bushing, gear teeth or release lever coupling groove. Check for excessive clearance between the sleeve and the reverse lever. Standard allowable clearance is 0.004-0.013 inch.