For 1990-2009 cars

1. Clean the following components:

1.1. | The bearings

1.2. | The shafts

1.3. | The sprockets

1.4. | The chain

1.5. | The oil feed ports and channels.

Apply compressed air to each oil feed port and each channel in both case halves in order to remove any obstructions or cleaning solvent residue.

1.6. | All mating surfaces.

2. Inspect the bearings and the thrust washers for the following conditions:

• | Wear

• | Spalling

• | Brinelling

• | Corrosion

3. Inspect the gear teeth for the following conditions:

• | Excessive wear or damage

• | Spalling

• | Cracks

• | Corrosion

4. Inspect the gear splines for the following conditions:

• | Excessive wear

• | Spalling

• | Cracks

• | Twist

• | Corrosion

5. Inspect the shaft spines for the following conditions:

• | Excessive wear

• | Spalling

• | Cracks

• | Distortion

• | Corrosion

6. Inspect the range fork and fork brushing for the following conditions:

• | Cracks

• | Excessive wear

• | Distortion

7. Inspect mode fork and rail assembly by installing it into the range fork assembly. Inspect the mode fork and rail assembly for the following conditions:

• | Any type of binding

• | Any type of misalignment

8. Inspect the retainer rings for the following conditions:

• | Excessive wear

• | Distortion

• | Damage

9. Inspect the case halves for the following conditions:

• | Damaged or warped mating surfaces

• | Cracks

• | Porosity

• | Damaged thread holes

10. Inspect the synchronizer assembly for the following conditions:

• | Cracks

• | Chips

• | Spalling

• | Excessive wear

11. Inspect the synchronizer hub and sleeve for the following conditions:

• | Cracks

• | Chips

• | Spalling

• | Excessive wear

12. Inspect the pads on the mode fork and on the range fork for the following conditions:

• | Excessive or uneven wear

• | Distortion

13. Inspect the oil pump gears, the housing and the mainshaft for the following conditions:

• | Wear

• | (Replace the complete assembly if there is wear.)

• | Spalling

• | Cracks

• | Damage

14. Inspect the following components for excessive wear:

• | The input gear

• | The planetary carrier

• | The range shift hub tooth chamfers