Assembly
TRANSMISSION ASSEMBLY
Assembly
SHAFT AND GEAR
1. Install main drive gear assembly, mainshaft assembly, and counter shaft assembly combined in one unit to adapter plate using a brass bar.
2. Install the adapter setting plate [SST] to adapter plate and then fixing in adapter setting plate using a vise.
CAUTION:
Never directly secure the surface in a vise.
3. Install magnet to adapter plate.
4. Install snap ring to mainshaft bearing.
CAUTION:
Never reuse snap ring.
5. Apply recommended grease to counter rear bearing.
6. Install counter rear bearing onto adapter plate using the drift
[SST].
CAUTION:
Replace counter rear bearing inner race, counter rear bearing and counter rear bearing spacer as a set.
7. Apply thread locking sealant to the end of bolts (first 3 to 4 threads).
- Use Genuine Medium Strength Thread Locking Sealant or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.
8. Install mainshaft bearing retainer to adapter plate and tighten bolts to the specified torque.
9. Install reverse coupling sleeve and reverse shifting inserts into reverse synchronizer hub.
CAUTION:
- Be careful with the orientation of reverse coupling sleeve.
- Never reuse reverse coupling sleeve and reverse synchronizer hub.
- Replace reverse coupling sleeve and reverse synchronizer hub as a set.
- Be careful with the orientation of reverse synchronizer hub.
- Be careful with the shape of 1st-2nd, 3rd-4th and 5th-6th shifting insert to avoid mis-assembly.
10. Install reverse spread springs to reverse shifting inserts.
CAUTION:
Never install reverse spread spring hook onto the same reverse shifting insert.
11. Install snap ring to reverse synchronizer hub.
CAUTION:
- Never align snap ring notch with synchronizer hub groove when assembling.
- Never reuse snap ring.
12. Apply gear oil to reverse main needle bearing and reverse baulk ring.
13. After installing reverse main gear bushing, reverse main needle bearing, reverse main gear and reverse baulk ring onto mainshaft using the press plate (A) [SST: KV32103300 (J-46529)], the drift (B) [SST: ST01530000 ( - )], and a press to press-fit reverse synchronizer hub assembly (1).
CAUTION:
Be careful with the orientation of reverse coupling sleeve.
NOTE:
Reverse baulk ring has three spaces that two gear teeth are missing, and each space has small ditch for identification as shown in the figure.
14. Select and install a snap ring so that the end play comes within the standard value.
End play standard value : Refer to End Play End Play
CAUTION:
Never reuse snap ring.
15. After installing counter rear bearing spacer, press and fit reverse counter gear onto counter shaft with drift [SST: ST23860000 ( -
)] and press.
CAUTION:
- Never reuse reverse counter gear.
- Replace counter rear bearing inner race, counter rear bearing and counter rear bearing spacer as a set.
- Be careful with the orientation of counter rear bearing spacer.
- Be careful with the orientation of reverse counter gear.
16. Select and install a snap ring so that the end play comes within the standard value.
End play standard value : Refer to End Play End Play
CAUTION:
Never reuse snap ring.
SHIFT FORK AND FORK ROD
1. Install 5th-6th shift fork to 5th-6th coupling sleeve.
2. Install 5th-6th fork rod (reversal side) to 5th-6th shift fork.
3. Using a pin punch [Commercial service tool] to tap retaining pin into 5th-6th shift fork.
CAUTION:
Never reuse retaining pin.
4. Install 5th-6th fork rod to adapter plate.
5. Install 5th-6th fork rod bracket to 5th-6th fork rod.
6. Using a pin punch [Commercial service tool] to tap retaining pin into 5th-6th fork rod bracket.
CAUTION:
Never reuse retaining pin.
7. Install 5th-6th control lever to adapter plate and then tighten mounting bolts to the specified torque.
CAUTION:
Set the projection upward.
8. Apply recommended grease check balls and then install check balls to adapter plate.
9. Install reverse shift fork to reverse coupling sleeve.
10. Install reverse fork rod to reverse shift fork.
11. Using a pin punch [Commercial service tool] to tap retaining pin into reverse shift fork.
CAUTION:
Never reuse retaining pin.
12. Apply recommended grease to interlock pin and interlock plunger.
13. Install interlock pin and interlock plunger to adapter plate.
14. Install 1st-2nd shift fork to 1st-2nd coupling sleeve.
15. Install 1st-2nd fork rod to 1st-2nd shift fork.
16. Using a pin punch [Commercial service tool] to tap retaining pin into 1st-2nd shift fork.
CAUTION:
Never reuse retaining pin.
17. Install 3rd-4th shift fork (1) to 3rd-4th coupling sleeve.
18. Install 3rd-4th fork rod (reversal side) (2) to 3rd-4th shift fork.
19. Using a pin punch [Commercial service tool] to tap retaining pin
( ) into 3rd-4th shift fork (reversal side).
CAUTION:
Never reuse retaining pin.
20. Apply recommended grease to interlock pin and check balls.
21. Install interlock pin and check balls to adapter plate.
22. Install 3rd-4th fork rod (1) to adapter plate.
23. Install 3rd-4th fork rod bracket (2) to 3rd-4th fork rod.
24. Using a pin punch [Commercial service tool] to tap retaining pin
( ) into 3rd-4th fork rod bracket.
CAUTION:
Never reuse retaining pin.
25. Apply recommended grease to check ball and then install check ball and check ball spring into adapter plate.
26. Apply recommended sealant to threads of check ball plugs and then tighten check ball plug to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.
27. Install shifter cap to 3rd-4th control lever.
28. Install 3rd-4th control lever to adapter plate and then tighten mounting bolts to the specified torque.
CAUTION:
- Make sure the top and bottom are oriented correctly.
- Never drop shifter cap.
29. Apply recommended grease to check ball and then install check balls and check ball springs into adapter plate.
30. Apply recommended sealant to threads of check ball plugs and then tighten check ball plugs to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.
31. Install low/high control lever to striking rod.
32. Using a pin punch [Commercial service tool] to tap retaining pin into low/high control lever.
CAUTION:
Never reuse retaining pin.
33. Install stopper ring to striking rod.
34. Using a pin punch [Commercial service tool] to tap retaining pin into stopper ring.
CAUTION:
Never reuse retaining pin.
35. Install striking rod to adapter plate.
36. Install striking lever to striking rod.
37. Using a pin punch [Commercial service tool] to tap retaining pin into striking lever.
CAUTION:
Never reuse retaining pin.
38. Install baffle plate to adapter plate and then tighten mounting bolts to the specified torque.
CASE AND EXTENSION
1. Apply recommended grease to roller of counter front bearing.
2. Install counter front bearing to transmission case.
3. Install oil gutter to transmission case.
4. Install breather tube to transmission case.
CAUTION:
Never reuse breather tube.
5. Apply recommended sealant to transmission case adapter plate mounting surface as shown in the figure.
- Use Genuine Silicone RTV or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to both mounting surfaces.
6. Place adapter plate in transmission case using a soft hammer to tap adapter plate to install it into transmission case.
7. Install snap ring to main drive gear bearing using a snap ring pliers.
CAUTION:
Never reuse snap ring.
8. Tighten baffle plate mounting nut to the specified torque.
9. Apply multi-purpose grease to lip of front cover oil seal.
10. Install front cover oil seal (1) to front cover using the drift (A)
[SST: KV38102100 (J-25803-01)].
Dimension "H" : 8.55 - 9.55 mm (0.3366 - 0.3760 in)
CAUTION:
- Never reuse front cover oil seal.
- When installing, never incline front cover oil seal.
11. Install front cover according to the following.
a. Install front cover gasket and front cover to transmission case.
CAUTION:
- Never reuse front cover gasket.
- Never damage front cover oil seal.
- Remove any moisture, oil, or foreign material adhering to both mating surfaces.
b. Temporary tightening mounting bolt ( ) and sealing bolt (1).
c. Temporary tightening remaining mounting bolts ( ) and sealing bolts (1).
d. Tighten mounting bolts ( ) and sealing bolts (1) to the specified torque in order as shown on the figure.
12. Apply gear oil to counter end bearing.
13. Install counter end bearing to rear extension.
CAUTION:
Never reuse counter end bearing.
14. Install rear extension oil gutter and cap to rear extension and then tighten mounting bolt to specified torque.
15. Install rear extension dust cover to rear extension.
16. Install bracket to transmission case and then tighten mounting bolt to specified torque.
17. Apply gear oil to reverse idler needle bearing.
18. Install reverse idler shaft, reverse idler needle bearing, reverse idler gear and reverse idler thrust washer to adapter plate.
19. Apply multi-purpose grease to striking rod oil seal lip.
CAUTION:
Never reuse striking rod oil seal.
20. Install striking rod oil seal to rear extension using the drift [SST:
ST33061000 (J-8107-2)].
CAUTION:
When installing, never incline striking rod oil seal.
21. Apply multi-purpose grease to lip of rear oil seal.
CAUTION:
Never reuse rear oil seal.
22. Install rear oil seal (1) to rear extension using the drift [SST:
ST33400001 (J-26082)].
Dimension "H" : 1.2 - 2.2 mm (0.047 - 0.087 in)
CAUTION:
When installing, never incline rear oil seal.
23. Apply recommended sealant to adapter plate rear extension mounting surface as shown in the figure.
- Use Genuine Silicone RTV or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to both mounting surfaces.
24. Install rear extension to adapter plate and then tighten mounting bolts to the specified torque in order as shown in the figure.
CAUTION:
Never damage rear oil seal and striking rod oil seal.
25. Install control lever housing to rear extension and then tighten mounting bolts to the specified torque.
CAUTION:
Never hold control lever housing to prevent the bushing of control lever housing from deformation when moving transmission assembly.
26. Apply gear oil to return spring plungers.
27. Install return spring plungers and return springs into rear extension.
CAUTION:
The right and left return springs and return spring plungers are different, so make sure they are installed correctly.
28. Apply recommended sealant to threads of return spring plugs and then tighten return spring plugs to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.
29. Install check shift pin as a one unit with control bracket to rear extension and then tighten mounting bolts to the specified torque.
30. Install plunger to rear extension and then screwing park/neutral position (PNP) switch and back-up lamp switch to rear extension with 1 - 2 pitches.
31. Apply recommended sealant to threads of switches and tighten switches to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.
32. Install brackets to rear extension and then tighten bracket mounting bolts to the specified torque.
33. Install boot and control rod to striking rod.
34. Install the retaining pin into the control rod using a pin punch
[Commercial service tool]. Then fit the boot to the striking rod oil seal and the groove on the control rod.
CAUTION:
Never reuse retaining pin.
35. Install boot to control rod.
CAUTION:
Fit the boot to the groove on the control rod.
36. Apply gear oil to check ball.
37. Install check ball and check select spring into rear extension.
38. Install rear extension upper cover gasket and rear extension upper cover to rear extension.
CAUTION:
- Never reuse rear extension upper cover gasket.
- Avoid tangling check select spring.
39. Tighten rear extension upper cover bolts to the specified torque in order as shown on the figure.
40. Install gasket to drain plug and then install it to transmission case. Tighten drain plug to the specified torque.
CAUTION:
Never reuse gasket.
41. Install gasket to filler plug and then install it to transmission case. Tighten filler plug to the specified torque.
CAUTION:
- Never reuse gasket.
- After oil is filled, tighten filler plug to specified torque.