For 1990-2009 cars

1. Clean the following components:

• | The bearings

• | Remove all of the old lubricant and any dirt.

• | The shafts

• | The sprockets

• | The chain

• | The oil feed ports and channels in each case half

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

• | All of the mating and sealing surfaces.

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

• | Spalling

• | Brinneling

• | 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 splines for the following conditions:

• | Excessive wear

• | Spalling

• | Cracks

• | Distortion

• | Corrosion

6. Inspect the retainer rings for the following conditions:

• | Excessive wear

• | Distortion

• | Damage

7. Inspect the case halves for the following conditions:

• | Damaged or warped mating surfaces

• | Cracks

• | Porosity

• | Damaged thread holes

8. Inspect the synchronizer stop rings for the following conditions:

• | Cracks

• | Chips

• | Spalling

• | Excessive wear

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

• | Cracks

• | Chips

• | Spalling

• | Excessive wear

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

• | Wear

• | Distortion

11. Inspect the oil pump gears and the case halves for the following conditions:

• | Spalling

• | Cracks

• | Damage

• | Wear

• | Replace the complete assembly if there is wear.

12. Inspect the following components for excessive wear:

• | The input gear

• | The planetary carrier

• | The range shift hub tooth chamfers