Transmission

Cleaning

1. Wash all parts except ball bearings, O-rings and seals in a suitable cleaning solvent. Brush or scrape all foreign matter from the parts. Be careful not to damage any parts with the scraper.

    CAUTION: Do not clean, wash or soak transmission seals in cleaning solvents. Dry all parts with compressed air.

2. Rotate ball bearings in a cleaning solvent until all lubricant is removed. Hold bearing assembly to prevent it from rotating and dry it with compressed air.

3. Lubricate bearings with Multi-Purpose Grease D0AZ-19584-AA (ESR-M1C159-A and ESB-M1C93-A) or equivalent, and wrap them in a clean, lint-free cloth or paper until ready for use.

4. Clean the magnet in the bottom of the case with kerosene or mineral spirits.

Inspection

1. Inspect transmission case for cracks, worn or damaged bearing bores, damaged threads, or any other damage that could affect operation of the transmission.

2. Inspect the front face of the case for small nicks or burrs that could cause misalignment of the transmission with the flywheel housing. Remove all small nicks or burrs with a fine file.

3. Replace any 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 lever and shafts.

5. Inspect the ball bearings. Refer to Ball Bearing Inspection.

6. Replace roller bearings that are broken, worn or rough, and check their respective races.

7. Replace the countershaft (cluster) gear if the teeth are chipped, broken or worn. Replace the countershaft 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 gear shaft if bent, worn or scored.

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 (if present) are properly indexed.

12. Inspect the synchronizer blocking rings for widened index slots, rounded clutch teeth, and smooth internal surfaces (must have machined grooves). With the synchronizer blocking ring on the cone, the distance between the face of the synchronizer blocking ring and the clutch teeth on the gear must not be less than 0.5mm (0.020 inch).

13. Replace speedometer drive gear if teeth are stripped or damaged. Make certain to install 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 bushing and seal in the extension housing, and replace if worn or damaged. The bushing and/or seal should be replaced after the extension housing has been installed on the transmission.

16. Replace the seal in the input shaft bearing retainer.

17. Replace seals on the cam and shafts.