Contents: Crankcase and covers ↓ Seals ↓ Shafts ↓ Gears ↓ Bearings ↓ Rods and forks ↓ Hubs, clutches and synchronizer…↓
Before inspection, the parts are thoroughly cleaned with a brush or scrapers, all deposits are removed, and holes and splines are cleaned of dirt. Then they are washed to remove all oil residues. The parts are blown with a stream of compressed air and carefully wiped. Bearings should be blown especially carefully, directing the stream of compressed air so that rapid rotation of the rings does not occur.
Crankcase and covers
There should be no cracks on the crankcase and no wear on the surface of the bearing bores (see table 8) or damage. There should be no damage on the mating surfaces with the clutch housing and covers that could cause the axles to diverge or that could cause insufficient sealing that could result in oil leakage. Minor damage can be removed with a file. If the parts are damaged or their wear exceeds the permissible limits specified in table 8, they are replaced with new ones.
Check the condition of the front cover and whether the drive shaft touches it when rotating. If the shaft and cover are not aligned, replace the damaged parts. Check whether the drain hole of the front cover is clogged and clean the drain plug of the gearbox.
Seals
The working edges must not have any damage or unevenness, the permissible wear of the working edge in width is no more than 1 mm. Even with minor damage, they are replaced with new ones.
(The article is copied from the website VAZbook.ru)
Shafts
The working surfaces and splines of the driven shaft must not be damaged or subject to excessive wear (see table 8); the flange of the flexible coupling must slide freely on the splines, without jamming. There must be no visible irregularities on the rolling surfaces of the needles at the front end of the driven shaft and in the holes of the driving shaft. The intermediate shaft must not have chipping or excessive wear of the teeth. The surface of the reverse gear axle must be smooth, without signs of jamming. Minor irregularities on the surfaces are removed with a set of sandpaper with a grain size of 10 to M40. In case of major damage and deformation, replace the shaft with a new one.
Gears
The gears are not allowed to have damage or wear of the teeth exceeding the values of the permissible lateral clearance in the engagement specified in Table 8. Particular attention is paid to the condition of the ends of the teeth on the synchronizer rims. The contact patch between the teeth of the gears in the engagement must extend over the entire working surface, which must be smooth, without visible signs of wear. In addition, the gap in the engagement between the gears is checked with an indicator (see table 8).
Bearings
Must be in perfect condition. Their radial clearance must not exceed 0.05 mm. When checking, press the inner ring to the outer ring with your fingers and turn one of them in both directions. In this case, the rolling must be smooth. No damage is allowed on the surface of the balls (rollers) and the raceways of the rings. Damaged bearings are replaced with new ones.
Rods and forks
Deformation of the gear shift forks is not allowed. The rods must slide freely without significant clearance in the crankcase holes. The condition of the rod locking crackers, springs and locking balls is checked. Parts that show signs of seizing or wear are replaced with new ones.
Hubs, clutches and synchronizer locking rings
Check for signs of seizing on the hubs of the gear engagement clutches, especially on the sliding surfaces of the clutches. Pay special attention to the condition of the ends of the clutch teeth.
Excessive wear of the surface of the locking rings when they rest against the synchronizer clutch is not allowed. Malfunctions that prevent free sliding are eliminated with a velvet file. Worn parts are replaced with new ones.