Manual Transmission Reassembly (6MT)

Manual Transmission Reassembly

NOTE:

- Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to any contact surfaces.
- Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Install the magnet (A) and the differential assembly (B).

NOTE: Clean the magnet anytime the transmission is disassembled.






2. Install the 28 mm spring washer (A) and the 28 mm washer (B) over the ball bearing (C).

NOTE: Be sure to install the spring washer in the direction shown.





3. Apply tape to the mainshaft splines (D) to protect the seal. Install the mainshaft assembly (E) and the countershaft assembly (F) with the shift fork assembly (G), as an assembly.

NOTE: Do not apply tape thick to damage the oil seal.

4. Install the reverse shift fork (A).






5. Install the reverse idler gear (A) and the reverse idler gear shaft (B) by aligning the mark (C) on the clutch housing with the reverse idler gear shaft hole (D).






6. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment M/T Mainshaft Thrust Clearance Adjustment (6MT). Install the oil gutter plate (B), oil guide plate M, and the 72 mm shim into the transmission housing (C).





7. Clean any dirt or oil from the mating surface of the transmission housing and the clutch housing.

8. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





9. Install the three 14 x 20 mm dowel pins (A).





10. Place the transmission housing over the clutch housing, making sure to line up the shafts.

11. While expanding the 72 mm snap ring (B) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.

NOTE: Install the 32 mm sealing cap (C) after setting in the 72 mm snap ring.

12. Make sure the 72 mm snap ring (A) is securely seated in the groove of the countershaft bearing.









13. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 to the threads of the 32 mm sealing cap, and install it on the transmission housing.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

14. Install the 8 mm flange bolts finger-tight with transmission hanger A, transmission hanger B.






15. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.









16. Clean any dirt or oil from the mating surface of the change lever assembly and the transmission housing.

17. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the mating surface of the charge lever assembly and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Allow it to cure at least 30 minutes after assembly before filling the transmission with MTF.





18. Install the 8 x 14 mm dowel pins (B), the change lever assembly (C), and harness bracket A.





19. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the threads of the interlock bolt (D), and install it on the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

20. Install the drain plug (A) and the 10 mm flange bolt (B) with new sealing washers (C). Install the filler plug (D) with a new sealing washer (E) finger-tight.





21. Apply MTF to a new O-ring (F). Then install the output shaft (countershaft) speed sensor (G) with the O-ring.

22. Install the steel balls (A), the detent ball springs (B), and the detent bolts (C) with new sealing washers (D). Install the transmission hanger (E).






23. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the threads of the back-up light switch (D), and install it on the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

24. Install the 20 mm bolt (A) and a new 20 mm sealing washer (B).