Install Snap Ring

(a) Select a snap ring that will allow minimum axial play.

>to*k

T tectums

mm (in.)

Mirk

Thicfcnei*

tw fin.)

5

2 25-

2 30 10 0836

-0 09061

17

2 61 -

2 66 <0 1028-

0.1047)

11

2 30-

2.35 (0 0906

- 0 0925)

18

2.67-

2.72 «0 105! -

0.1071)

12

2 35-

2 40 (0 0925

- 0 0945)

19

2 73-

2 78 (0 107S-

0 1094)

13

240-

2 45 (0 0945

- 0 0966)

20

2 79 -

2 84 (0 1098 -

0.1118)

14

2 45 -

2 50 (0.0965

-0 0984)

21

2 85 -

2 90 CO 1122 -

0.1142)

IS

250-

2.55 (0 0984

-0.1004)

22

2 91 -

296(01146-

0 1166)

16

256 -

2 GO <0.1004

- 0.1024)

23

2.97 -

3.02 (01169-

0.1189)

(bl Using a snap ring pliers, install snap ring.

(bl Using a snap ring pliers, install snap ring.

6. INSTALL FIFTH GEAR AND OUTPUT SHAFT REAR BEARING

Using SST, install the 5th gear and rear bearing. SST 09312 20011

7. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play.

7. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play.

Mirk

Thxfcntu

men (in )

Thtckntu

mm {•*.)

8

2.31 -

2 36 <0 0909

-0 0929)

12

2 55 -

2 60 10 1004

-0 1024)

0

2 37 -

2 42 <0 0933

- 0 0953)

13

2 61 -

2.66 <0 1028

- 01047)

10

2.43-

2.48 <0 0957

- 0 0976)

14

2 68 -

2 73 (0 1055

-0 1075)

11

2 49 -

2.54 <0 0980

-0 1000)

15

2 74-

279 10 1079

-0.1098)

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(b) Using a screw driver and hammer, install snap ring.

8. INSTALL NO.3 CLUTCH HUB

Using SST, drive in No.3 clutch hub. SST 09316-60010 (09316 00010, 09316-00070) HINT: When installing the clutch hub, support the countershaft in front with a 3-5 lb hammer or equivalent.

9. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play.

Mark

Thickness

mm (in.)

2

2.06 - 2.11 (0.0811

- 0.0831)

3

2.12 - 2.17 (0.0835

- 0.0854)

4

2.18 - 2.23 (0.0858

- 0.0878)

s

2.24 - 2.29 (0.0882

0.0902)

(b) Using a screwdriver and hammer, install snap ring.

10. INSTALL SPACER, SYNCHRONIZER RING. NEEDLE ROLLER BEARING AND COUNTER FIFTH GEAR

<a) Install the bearing spacer.

(b) Apply gear oil to the needle roller bearings.

(c) Assemble the counter 5th gear, synchronizer ring and needle roller bearings.

(d) Install the 5th gear assembly with the synchronizer ring slots aligned with the shifting keys.

11. INSTALL SPACER AND BEARING

(a) Install the spacer.

<t>) Install the bearing with the ball shield toward the rear.

(c) Using a hammer and socket wrench, drive in the bearing.

HINT: When driving in the bearing, support the countershaft in front with a 3-5 lb hammer or equivalent.

12. INSTALL SNAP RING

(a) Select a snap ring that will allow minimum axial play.

Thickoest mm (in. 11 Mark

Thicfcont mm <tfO

2 1 96-2 0M0 0772-0 07911 6

4 j2 08- 2.13 <0 0819-0 08»|j^

2.14 - 2.19 <0 0843 - 0 08621 220 - 2 25 <0 0666 - 0 0886) 2 26 - 231 10 0890 0 0909)

(b) Using a snap ring pliers, install snap ring.

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13. INSTALL SPEEDOMETER DRIVE GEAR

(a) Put a clip on the output shaft and install the drive gear clip into the slot.

(b> Slide the drive gear with clip and fit the clip into the holes.

14. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE

Using a feeler gauge, measure counter 5th gear thrust clearance.

Standard clearance:

15. INSTALL SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR

(a) Install the reverse idler gear and shaft.

(b) Install No.3 shift fork. No.3 fork shaft and reverse shift arm.

< 1) Coat the pin with MP grease and insert it into the reverse shift head hole.

(2) Insert No.3 shift fork shaft through No.3 shift fork and the reverse shift arm.

(3) Align No.3 shift fork with the No.3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove.Install No.3 shift fork shaft to the intermediate plate.

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(c) Install No.4 shift fork shaft.

< 1) Push the pin. which was inserted into the reverse shift arm hole, into the groove of No.3 shift fork shaft.

(2) Insert No.3 shift fork shaft through No.3 shift fork and the reverse shift arm.

(3) Align No.3 shift fork with the No.3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove. Install No.3 shift fork shaft to the intermediate plate.

(d) Using a pin punch and hammer, drive in the slotted spring pin until it is flush with the fork.

(e) Apply MP grease No.3 interlock pin and install the pin into the intermediate plate hole.

(f> Install No.2 shift fork and fork shaft.

(1) Apply MP grease to No. 2 interlock pin and install the pin into the shaft hole.

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(2) Place No.2 shift fork into the groove of No.2 hub sleeve.

(3) Install No.2 fork shaft to the shift fork through the intermediate plate.

(g) Install the snap ring of No.2 fork shaft.

(h) Apply MP grease to No. 1 interlock pin and install the pin into the intermediate plate.

(i) Install No.1 shift fork and fork shaft.

(1) Install No. 1 shift fork into the groove of No. 1 hub sleeve.

(2) Insert No.1 fork shaft to the shift fork through the intermediate plate.

(j) Install the snap ring of No.1 fork shaft.

(kl Install the No. 1 and No.2 shift fork set bolts with lock washers.

0) Using pliers, stake the bolts with lock washers.

16. INSTALL LOCKING BALL AND SPRING

(a) Install the balls and spring into each hole.

(b) Apply liquid sealer to the plug threads.

Sealant: Part No. 08833 00080, THREE BOND 1344. LOCTITE 242 or equivalent

(c) Using SST, tighten the four plugs. SST 09313-30021

17. INSTALL REVERSE IDLER GEAR SHAFT STOPPER

Install the reverse idler gear shaft stopper and tighten the bolt.

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18. DISMOUNT INTERMEDIATE PLATE FROM VISE

(a) Dismount the intermediate plate from the vise.

(b) Remove the bolts, nuts, plate washers and gasket.

19. INSTALL TRANSMISSION CASE TO INTERMEDIATE PLATE

(a) Apply seal packing to the transmission case as shown.

Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

(a) Align each bearing outer race and each shift fork shaft end with the case holes.

(b) Using a plastic hammer, tap on the case to install it.

20. INSTALL BEARING SNAP RINGS

Using snap ring pliers, install the two snap rings.

21. INSTALL FRONT BEARING RETAINER

(a) Apply seal packing to the retainer as shown, and install it to the transmission case.

Seal packing: Part No. 08826 00090, THREE BOND 1281 or equivalent

(b) Apply liquid sealer to the bolt threads.

Sealant: Part No. 08833-00080. THREE BOND 1344, LOCTITE 242 or equivalent

(c> Install and torque the bolts.

22. INSTALL EXTENSION HOUSING

(a) Insert shift and select lever into the extension housing.

(b) Apply seal packing to the extension housing.

Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

(c) Connect the shift and select lever to the shift fork shaft.

(d) Install shift lever housing to shift and select lever shaft, push in the extension housing.

(e) Install and torque the bolt. Torque: 400 kg-cm (29 ft-lb, 39 N-m)

(f) Install nine bolts to the extension housing.

(g) Torque the bolts.

23. AFTER INSTALLING EXTENSION HOUSING. CHECK FOLLOWING ITEMS:

(a) Check to see that input shaft and output shaft rotate smoothly.

(b) Check to see that shifting can be made smoothly to all positions.

24. INSTALL RESTRICT PINS

(a) Install the restrict pins together with a gasket.

HINT: Install the black pin on the reverse gear/5th gear side.

<b) Torque the restrict pins. Torque: 410 kg-cm (30 ft-lb. 40 N-m)

25. INSTALL CLUTCH HOUSING

(a) Install the clutch housing.

<b) Install and torque the nine bolts.

26. INSTALL SHIFT LEVER RETAINER

(a) Install the shift lever retainer with a oil baffle.

(b) Install and torque the six bolts. Torque: 185 kg-cm (13 ft-lb. 18 N-m)

27. INSTALL SPEEDOMETER DRIVEN GEAR

(a) Install the speedometer driven gear.

(b) Install the bolt with lock plate.

(c) Torque the bolt.

28. INSTALL BACK UP LIGHT SWITCH

(a) Install and torque the back-up light switch. Torque: 410 kg-cm (30 ft-lb, 40 N-m)

(b) Install the wire clamp.

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