Reassembly

Reassembly

1. Reassembly the main drive shaft and the count shaft to the intermediate plate.
2. Install the snap rings each to the main drive shaft and the count shaft.








3. Install the 5&6th shift rail with the nut.

Tightening torque:
15 - 22 Nm (1.5 - 2.2 kgf.m, 10.8 - 15.9 lb-ft)





4. Install the bearing retainer by installing the bolts(8ea) with TORX wrench.

Tightening torque:
20 - 27 Nm (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)


CAUTION:
Be sure to replace the retainer bolt with a new one.




5. After installing the shift rails with hammer and chisel, install the 1&2nd and 3&4th forks with spring pins.




6. Install the control shaft assembly (A) and install the stopper lever (B) with a pin.








7. Insert the retainer ring as shown in the illustration.

CAUTION:
Be sue not to reuse the retainer ring.




8. Install the oil guide by installing the bolts(2ea).

Tightening torque:
8 - 10 Nm (0.8 - 1.0 kgf.m, 5.79 - 7.23 lb-ft)





9. Install the oil guide.




10. Apply the specified sealant on the contact surface of the transmission housing.

Specified sealant : MS 721-40





11. Install the intermediate plate to the transmission case.

CAUTION:
Be careful not to damage to the plastic oil guide.




12. Install the 5&6th shift rug.




13. Install the 4th speed gear and spacer of the main shaft.




14. Install the needle roller bearing.




15. Install the 4th gear assembly and synchronizer ring.




16. Install the 3&4th synchronizer hub.

CAUTION:
Place the chamfer inside of the synchronizer hub downward.




17. Install the 3th gear sleeve by using the special service tool(09432-25200).




18. Install the 3&4th synchronizer sleeve with the shift fork.

CAUTION:
Place the groove of the synchronizer sleeve upward.





NOTE:
Check that the position of shift forks is correct as shown in the illustration.




19. Install the synchronizer keys (3 places).




20. Install the synchronizer ring assembly.




21. Install the needle roller bearing.




22. Install the 3rd gear assembly.




23. Install the count shaft reverse gear.

CAUTION:
Place the chamfer inside of the gear toward the engine side.




24. Install the 3rd speed gear of main shaft.




25. Install the reverse gear sleeve by using the special service tool(09432-25300).




26. Install the needle roller bearing.




27. Install the reverse gear assembly and synchronizer ring.




28. Install the reverse synchronizer hub and sleeve.

CAUTION:
Be careful not to be upside down.








29. Install the synchronizer keys(3 places) and the key stopper (snap ring).




30. Install the ball bearing.




31. Install the reverse idler shaft.




32. Install the reverse idler gear.




33. Install the needle roller bearing.




34. Install the reverse spacer.




35. Install the locking nut to the count shaft assembly and caulk at 2 points.

Tightening torque:
160 - 190 Nm (16 - 19 kgf.m, 115 - 137 lb-ft)


CAUTION:
Be sure to replace the locking nut with a new one.
Be careful not to damage to bearing contacting surface of the shaft.




36. Install the 5&6th shift lever assembly by installing the bolts(2ea).




37. Install the reverse shift rug.




38. Install the reverse shift fork.




39. Install the oil seals (2ea) each to the extension housing by using the special service tool(09452-25100, 25400).

CAUTION:
Apply lithium grease to lip of the oil seal as required.




40. Apply the specified sealant on the contact surface of the extension housing.

Specified sealant : MS 721-40





41. Install the extension housing by using a rubber hammer.

CAUTION:
Be careful the reverse fork not to be pulled out.

42. Install the extension housing assembly by installing the bolts(12ea).

Tightening torque:
43 - 55 Nm (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)









43. Install the snap ring to the main drive pinion assembly.




44. Install the spacer to the front bearing retainer assembly.




45. Apply the specified sealant on the contact surface of the front bearing retainer assembly.

Specified sealant : MS 721-40





46. Install the front bearing retainer assembly by installing the bolts(8ea).

Tightening torque:
20 - 25 Nm (2.0 - 2.5 kgf.m, 14.5 - 18.1 lb-ft)


CAUTION:
Be sure to use new bolts.




47. Install C.S.C. assembly by installing the bolts(3ea).

Tightening torque:
10 - 12 Nm (1.0 - 1.2 kgf.m, 7.23 - 8.68 lb-ft)


NOTE:
Install the rubber to the transmission case.




48. Install the inter lock plate bolt and guide bolt.

Tightening torque:
15 - 22 Nm (1.5 - 2.2 kgf.m, 10.8 - 15.9 lb-ft)


CAUTION:
Be sure not to switch the bolts, because two bolts are simillar but not the same.
Be sure to use new bolts.




49. Install a new poppet ball bearing assembly.

Tightening torque:
30 - 42 Nm (3.0 - 4.2 kgf.m, 21.7 - 30.4 lb-ft)





50. Install the bolts for retaining the reverse shift fork on both sides of the extension housing.

Tightening torque:
55 - 69 Nm (5.5 - 6.9 kgf.m, 39.8 - 49.9 lb-ft)


NOTE:
Check that the holes aligns the reverse shift fork and the transmission housing.








51. Apply the specified sealant on the contact surface of the dust cover.

Specified sealant : MS 721-40





52. Install the flange assembly by installing the locking nut(35mm) and caulk at 2 points.

Tightening torque:
250 - 270 Nm (25 - 27 kgf.m, 181 - 195 lb-ft)


CAUTION:
Be careful not to damage the oil seal inside of the dust cover.
Be sure to use a new O-ring and a new locking nut.




53. Install the back up lamp switch with a new gasket.

Tightening torque:
30 - 35 Nm (3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)


CAUTION:
Be sure to use a new gasket.




54. Install the seal plug with the rolling plunger and guide spring.

Tightening torque:
55 - 69 Nm (5.5 - 6.9 kgf.m, 39.8 - 49.9 lb-ft)


NOTE:
Install the bracket holding the back up lamp switch connector with the seal plug.

CAUTION:
Be sure to use a new seal plug.