Inspection Procedure.

TM 9-2520-246-34

distorted or damaged.

inspected to determine serviceability. Some wear or

damage will be visually evident; however, it may be

(6) Expansion Plugs. Replace all expansion

necessary to use tools or gages to, determine the extent

plugs.

of wear. The inspection procedure has two objectives:

the first is to eliminate any part or parts that are

(7) Retaining Nuts. Replace retaining nuts that

unsuitable for use or doubtful parts that could

have damaged threads, cuts, or cracks.

conceivably cause the premature failure of the rebuilt

unit; the second, and equally important, is to reduce

scrapping of parts that retain a high percentage of

(8) Gearshafts. Inspect gearshafts for gall marks

or flat spots. Check gearshafts for fit as outlined in

useful life. Because the decision whether a part should

para b(1) above. Check bearing-to-shaft fit. Refer to

be scrapped or reused is frequently a matter of

repair and rebuild standards. Smooth any minor

judgment, this operation should be performed by

imperfections with crocus cloth or honing stone.

personnel experienced in the maintenance of

Reject for any other damage. Shafts that are scored or

transmissions, transfers, and power takeoffs.

pitted must be replaced.

(3) Instructions for the removal of minor

{9) Gears. The experience and good judgment of

imperfections and defects are included in this section

the inspector are required to a greater degree in

because they facilitate the inspection procedure. Every

judging gears than in any other operation. It is not

part which requires it must be washed, rinsed, and

possible to give arbitrary instructions as to when a

dried upon completion of the repair.

particular condition makes a gear unfit for further

use. The major and minor defects can only be pointed

b. Inspection Procedure.

out, leaving the in-between scrap or salvage decision

to the discretion of the individual.

(1) Casting. Inspect all gasket surfaces, all

bearing caps and shifter shaft covers. Remove any

(a) Small nicks or burs on the engaging ends of

burs, scratches, or gouges from these surfaces with a

the teeth may be removed with a small honing stone.

hand-honing stone. Clean all burs or foreign material

This is only practical for minor defects. Fractures of

from snapring grooves and expansion plug grooves.

the teeth are cause for rejection.

Check the cases for cracks or small pin holes, paying

particular attention to areas that were marked for

(b) Teeth which are fractured or burred must be

attention prior to initial cleaning. Cracks that do not

examined very carefully. Small burs may be removed

extend into bearing bores or mounting holes may be

by honing. Fractured areas, provided there are no

repaired. Refer to TM 9-237 for procedures for

hairline cracks radiating away from the area, may also

welding or brazing cast iron. Check and clean all

be smoothed by honing.

tapped holes. Mark any damaged holes or damaged or

broken studs for repair. Try the gearshafts in the shaft

bores of the cases. The shafts should be a snug fit in

rejection.

both the front and rear bore. If there is loose fit in

(d) When the hubs of gears are scored, gouged,

any bore, try a new, unused shaft in the bore. Discard

or burred seriously, the gears must be discarded.

either the case or the old gearshaft, whichever is found

Minor imperfections may be smoothed out by honing.

to cause looseness.

Excessive wear will be revealed when end play is

(2) Clutch Housing. Inspect the clutch housing

checked during the subsequent assembly operations.

for breaks or cracks. Small cracks that do not extend

(e) Examine the internal splines of all sliding

into the mounting holes may be repaired by welding.

gears. Twisted or broken splines are cause for

(3) Bearing Caps. Press the oil seal from the

rejection. Remove minor defects by honing. The

main shaft rear bearing cap, and discard the seal.

inspection of splines is discussed in para (10) below.

Inspect all bearing caps for burs, gouges, or scratches

on the gasket surface, and smooth out with hand-

(10) Mainshafts and Output Shafts. Inspect

bearing journals; reject for obvious defects such as

honing stone if necessary.

scored or galled spots or wear beyond limits specified

(4) Gear Spacers and Thrust Washers. Replace

in the repair and replacement standards contained in

the respective chapter for each assembly. Inspect

all main shaft gear spacers, bearing spacers, and thrust

washers.

threads on output end of shaft. Clean any flattened

threads with a three-cornered file and wrap the

(5) Snaprings. Replace all snaprings. Snaprings

threads with three or four turns of friction tape as a

furnished as part of ball bearings may be reused if not

protective measure against further damage until the

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