Crankcase and covers. There should be no cracks on the crankcase and covers, and no wear or damage is allowed on the surface of the bearing bores (dents, chips). Damage to the surfaces where the crankcase and covers meet may cause shaft misalignment and oil leakage. File off minor damage. If there is damage or extreme wear, replace the parts with new ones.
Oil seals. Check their condition carefully. If even minor damage is detected, replace the oil seals with new ones. The wear width of the working edge of the oil seal should not exceed 1 mm.
Shafts. No damage is allowed on the working surfaces, threaded part and splines of the shafts. Check the runout of the drive shaft and the front and rear axle drive shafts by installing them on prisms and turning them manually. The runout of the end part of the thrust belts for bearings should be no more than 0.01 mm.
When checking the intermediate shaft, pay attention to the condition of the gear block and the speedometer drive pinion. No chipping or excessive wear of the teeth is allowed. Replace any defective parts.
Gears. When inspecting gears, check the condition of the teeth and mounting surfaces. Chipping of teeth and their excessive wear are not allowed. There should be no scoring or wear marks on the mounting surfaces of the gears that cause a large gap.
Check the clearance in the gear engagement; the installation gap should be 0.10 mm, the maximum permissible is 0.20 mm.
The mounting clearance between the low gear pinion and the bushing, as well as between the drive shaft and the high gear pinion, should be 0.05-0.10 mm, the maximum permissible is 0.15 mm. If wear exceeds the permissible limits, replace the gears with new ones.
Bearings. Ball and roller bearings must not have damage on the raceways of the rings, on the separators, rollers or balls, as well as cracks and chips on the rings. The radial clearance of the bearings must not exceed 0.05 mm.
When turning, a clean, dry bearing should not knock. The movement should be smooth, without jamming. Replace damaged bearings.
Rods, forks. Deformation of forks and rod jamming in crankcase holes are not allowed. Replace retainer parts with new ones if signs of jamming are detected. Also replace retainer springs if they lose elasticity. Spring length under load 99.15...114.85 N (10.2...11.8 kgf) should be 19 mm, in a free state - 23.3 mm.
Hubs, couplings. Check for signs of seizing on the hub of the gear engagement coupling, especially on the sliding surfaces of the couplings, as well as on the splines of the differential housing. Clean up burrs and nicks with a file. Pay special attention to the condition of the ends of the coupling teeth; if they are damaged or crushed, preventing it from moving when shifting, replace the clutch.
Differential. Check the condition of the surface of the satellite shaft and the holes in the differential housing; if there is any damage, replace the parts with new ones.
Check the condition of the surface of the axle drive gear journals and their mounting holes in the differential housings, as well as the condition of the bearing surfaces on the adjusting washers and the mating end surfaces on the axle drive housings and gears. Replace the parts if there is damage or extreme wear.
With spring washer 14 removed (see figure 3-36) make sure that there is no radial movement of the retaining rings 8 in the grooves of the axle 13. If any play is detected, replace the retaining rings.
[The original material is located on the website: «chevyman»]