INSPECTION AND REPAIR
Inspect bearings (4 and 21) by rotating and checking that it turns
smoothly. Check bearing balls and rollers for flat areas, pitting,
scored, scratched, chipped, or cracked races.
Inspect clutch plates (18 and 19) for burrs, embedded metal particles,
severely pitted faces, cracks, distortion, or damaged ears.
Check clutch plates (18 and 19) using a straight edge to be sure they are
flat. If clutch plate is not flat, replace it.
Check clutch plates (18) for smooth or almost smooth surface. If smooth
or almost smooth surface is seen, replace clutch plate.
Using micrometer, measure clutch plate (18) thickness. If thickness is
less than 0.130 inch, replace clutch plate (18).
Using micrometer, measure clutch plate (19) thickness. If thickness is
less than 0.097 inch, replace clutch plate (19).
Using bore gage and micrometer, measure and record inside diameter of
Using micrometer, measure outside diameter of non-splined end of high
range clutch hub (20). Subtract this measurement from the measurement of
step (7) above to obtain clearance of high range clutch hub (20). If
clearance exceeds 0.005 inch, bushing (11) must be replaced. Use hammer
and chisel to cut bushing then remove it. Using 1-1/16 inches diameter
rod, press new bushing into housing (12) until bushing is 0.040 to 0.080
inch below surface of hub.
Replace an item if inspection indicates need for replacement.
Inspect transfer gear (23) for cracks or chipped, nicked, burred, broken,
or missing teeth. Check pins (22) for damage. If pins are damaged press
from gear using hydraulic press. Press new pins into gear until pins are
0.74 to 0.76 inch above surface of gear.
Inspect high range clutch piston housing (12), high range clutch piston
(7), and high range clutch hub (20) for cracks or distortion.
Inspect all other parts for distortion, excessive wear. or thread damage.