Crankcase and covers
There must be no cracks on the crankcase and covers, no wear or damage on the surface of the bearing bores (dents, chips). Damage to the crankcase-bonnet mating surfaces can cause shaft misalignment and oil leakage. Clean up minor damage with a file. If there is significant damage or wear, replace the parts with new ones.
Oil seals
Check their condition carefully. If even minor damage is found, replace the seals with new ones. The wear width of the working edge of the stuffing box should not exceed 1 mm.
Shafts
No damage is allowed on working surfaces, threaded parts and shaft splines. Check the runout of the drive shaft and drive shafts of the front and rear axles by mounting them on prisms and turning them by hand. The runout of the end part of the thrust belts for bearings must be more than 0.01 mm.
When checking the intermediate shaft, pay attention to the condition of the gear assembly and the speedometer drive gear. No chipping or excessive tooth wear is allowed. Replace defective parts.
Gears
When inspecting the gears, check the condition of the teeth and seating surfaces. It is not allowed to chip the teeth, their excessive wear. The seating surfaces of the gears must be free of nicks or wear that cause large clearance.
Check the clearance in the gear engagement; the mounting gap should be 0.10 mm, the maximum allowable gap is 0.20 mm.
The mounting gap between the low gear and the bushing, as well as between the drive shaft and the high gear should be 0.05-0.10 mm, the maximum allowable is 0.15 mm. If the wear exceeds the allowable limits, replace the gears with new ones.
Bearings
Ball and roller bearings must be free from damage on the raceways of the rings, cages, 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 move should be smooth, without jamming. Replace damaged bearings.
Rods, forks
Deformation of the forks and jamming of the rods in the openings of the crankcase are not allowed. Replace the fastener parts with new ones if traces of jamming are found. Also replace springs of clamps at loss of elasticity. Spring length under load 107±7.85 N (11±0.8 kgf) should be 19 mm, in the free state - 23.3 mm.
Hubs, couplings
Check for signs of seizing on the clutch hub, and especially on the sliding surfaces of the clutches, as well as on the splines of the differential case. Remove nicks and burrs with a file. Pay special attention to the condition of the ends of the coupling teeth; if they are broken or crushed, which prevents it from moving when shifting, replace the clutch.
Differential
Check up a condition of surfaces of an axis of satellites and apertures in satellites; in case of minor damage, sand the surfaces with fine-grained sandpaper, and in case of significant damage, replace the parts with new ones.
Check the condition of the surfaces of the journals of the axle drive gears of their mounting holes in the differential housing, the condition of the surfaces of the bearing washers of the axle drive gears, as well as the bearing surfaces of the differential housing for the satellites. Eliminate the detected damage with a fine-grained sandpaper or a velvet file; Replace severely damaged or worn parts.
With spring washer 15 removed (see fig. 3-45) make sure that there is no radial movement of the retaining rings 8 in the grooves of the axle 14. If play is detected, replace the retaining rings.