For 1990-2009 cars

### Clutch Housing

1. Clean the clutch housing in a suitable cleaning solvent and air dry.
2. Inspect the clutch housing for the following conditions:

• | Cracks

• | Damaged mounting flanges

• | Damaged bolt holes

Notice: Refer to Machined Surface Damage Notice in the Preface section.

3. Remove the sealer from the case sealing surfaces.
4. Inspect the case for being broken or cracked.
5. Inspect the bearing bore for the following conditions:

• | A spun bearing

• | Cracks

6. Replace the case assembly if any of the above conditions are found.
7. Inspect the sealing surfaces for damage.
8. Repair small scratches or nicks with a soft stone.
9. Inspect the case threaded bolt holes for damage.
10. Repair any damaged threads.
11. Inspect the location pins for being loose or missing.
12. Repair or replace any damaged location pins.

### Middle Case

1. Clean the middle case in a suitable cleaning solvent and air dry.

Notice: Refer to Machined Surface Damage Notice in the Preface section.

2. Remove the sealer from the case sealing surfaces.
3. Inspect the case for being broken or cracked.
4. Inspect the input shaft bearing bore for the following conditions:

• | A spun bearing

• | Cracks

5. Inspect the countershaft front bearing bore for the following conditions:

• | A spun bearing

• | Cracks

6. Replace the case assembly if any of the above conditions are found.
7. Inspect the sealing surfaces for damage.
8. Repair small scratches or nicks with a soft stone.
9. Inspect the case threaded bolt holes for damage.
10. Repair any damaged threads.
11. Inspect the location pins for being loose or missing.
12. Repair or replace any damaged location pins.

### Rear Case

1. Clean the rear case in a suitable cleaning solvent and air dry.

Notice: Refer to Machined Surface Damage Notice in the Preface section.

2. Remove the sealer from the case sealing surfaces.
3. Inspect the sealing surfaces for damage.
4. Inspect the case threaded bolt holes for damage.
5. Repair any damaged threads.
6. Inspect the location pins for being loose or missing.
7. Repair or replace any damaged location pins.
8. Inspect the shift shaft bushings for excessive wear.
9. Inspect the bearing bore.
10. Replace the case assembly if the shift shaft bushings are faulty.

### Extension Housing

1. Clean the extension housing in a suitable cleaning solvent and air dry.

Notice: Refer to Machined Surface Damage Notice in the Preface section.

2. Remove the sealer from the extension sealing surfaces (2).
3. Inspect the sealing surfaces for damage.
4. Inspect the extension for being broken or cracked.
5. Inspect the oil seal (1) for wear or damage. The oil seal is serviced only with the extension housing.
6. Inspect the bearing bore.
7. Replace the extension if any of the above conditions are found.
8. Inspect the case threaded bolt holes for damage.
9. Repair any damaged threads.
10. Repair or replace any damaged location pins.