Case 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. In the presence of damage or extreme 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. Damage must not be 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 should be no 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 marks that cause excessive play.
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 not show any 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 parts of the clamps with new ones if traces of jamming are found. Also replace springs of clamps at loss of elasticity. Spring length under load 99.15...114.85 N (10.2...11.8 kgf) should be 19 mm, in the free state - 23.3 mm.
Hubs, couplings. Check for signs of seizing on the shift clutch hub, especially on the sliding surfaces of the clutches, as well as on the splines of the differential housing. 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 a surface of an axis of satellites and apertures in the case of differential; If damaged, replace 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 end surfaces mating with them on the axle drive housings and gears. Replace parts if damaged or worn to the limit.
With spring washer 14 removed (see fig. 3-36) make sure that there is no radial movement of the circlips 8 in the grooves of the axle 13. If play is found, replace the circlips.