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 [SST] using a vise.

CAUTION:
Never directly secure the surface in a vise.





3. Install snap ring to mainshaft bearing.

CAUTION:
Never reuse snap ring.
4. Apply recommended grease to roller of counter rear bearing.





5. Install counter rear bearing to adapter plate using the drift [SST].

CAUTION:
Replace counter rear bearing inner race, counter rear bearing, and counter rear bearing spacer as a set.
6. Install bearing retainer with the following procedure.
a. Apply thread locking sealant to the end of bearing retainer mounting bolts (first 3 to 4 threads).
- Use Genuine Medium Strength Thread Locking Sealant or an equivalent. Fluid Type Specifications.

CAUTION:
Remove old sealant and oil adhering to threads.





b. Install bearing retainer to adapter plate and then tighten mounting bolts ( ) to the specified torque.
7. Install reverse synchronizer hub with the following procedure.
a. Install reverse coupling sleeve and reverse shifting inserts to reverse synchronizer hub.

CAUTION:





- Be careful with the orientation of reverse coupling sleeve.

White arrow: Reverse main gear side

- 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.

A : Reverse main gear side
B : Snap ring side





- Be careful with the shape of reverse shifting insert.
b. Install reverse spread springs to reverse shifting inserts.

CAUTION:





Never install reverse spread spring hook onto the same reverse shifting insert.
c. Install snap ring to reverse synchronizer hub.

CAUTION:
- Never reuse snap ring.





- Never align snap ring notch ( ) with synchronizer hub groove when assembling.





8. Install reverse synchronizer hub assembly (1) with the following procedure.

2 : Collar of mainshaft
3 : 6th main gear
4 : 2nd main gear
B : Drift [SST: ST01530000 ( - )]

a. Set the press plate (A) [SST: KV32103300 (J-46529)] to mainshaft as shown in the figure.
b. Apply gear oil to reverse needle bearing and reverse baulk ring.
c. Install reverse needle bearing, reverse main gear, and reverse baulk ring to mainshaft.

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.
d. Install reverse synchronizer hub assembly to mainshaft with a pressing machine using the drift [SST: ST01530000 ( - )].

CAUTION:





Be careful with the orientation of reverse coupling sleeve.

White arrow: Reverse main gear side






9. Select and install snap ring (1) so that the end play "L" of mainshaft is adjusted to the standard value. For selecting snap ring, refer to the latest parts information.

2 : Reverse synchronizer hub

End play "L" : Refer to TM-102, "End Play". End Play

10. Install reverse counter gear with the following procedure.
a. Install counter rear bearing spacer to counter shaft.

CAUTION:





- Be careful with the orientation of counter rear bearing spacer.

White arrow: Counter rear bearing side

- Replace counter rear bearing inner race, counter rear bearing, and counter rear bearing spacer as a set.





b. Install reverse counter gear (1) to counter shaft with a pressing machine using the drift (A) [SST: ST23860000 ( - )].

CAUTION:
- Never reuse reverse counter gear.





- Be careful with the orientation of reverse counter gear.

White arrow: Counter rear bearing side






11. Select and install snap ring (1) so that the end play "L" of counter shaft is adjusted to the standard value. For selecting snap ring, refer to the latest parts information.

2 : Reverse counter gear

End play "L" : Refer to TM-102, "End Play". End Play

SHIFT FORK AND FORK ROD





1. Install 5th-6th shift fork (1) and 5th-6th fork rod (reversal side)
(2) and then install retaining pin ( ) to 5th-6th shift fork using a pin punch [Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of 5th-6th shift fork and
5th-6th fork rod (reversal side).
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 5th-6th shift fork.





2. Install 5th-6th control lever to adapter plate and then tighten mounting bolts to the specified torque.

CAUTION:
Set the projection (A) upward.





3. Install 5th-6th fork rod bracket (1) and 5th-6th fork rod (2) and then install retaining pin ( ) to 5th-6th fork rod bracket using a pin punch [Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of 5th-6th fork rod bracket and 5th-6th fork rod.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 5th-6th fork rod bracket.





4. Apply recommended grease to check balls (1) and then install its to adapter plate.

A : View from transmission rear side


CAUTION:
Never drop check ball.
5. Apply recommended grease to interlock pin and then install it to reverse fork rod.

CAUTION:
Never drop interlock pin.





6. Install reverse shift fork (1) and reverse fork rod (2) and then install retaining pin ( ) to reverse shift fork using a pin punch
[Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of reverse shift fork and reverse fork rod.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of reverse shift fork.
- Never drop reverse coupling sleeve.





7. Apply recommended grease to interlock plunger (1) and then install it to adapter plate.

A : View from transmission rear side

8. Apply recommended grease to interlock pin and then install it to
1st-2nd fork rod.

CAUTION:
Never drop interlock pin.





9. Install 1st-2nd shift fork (1) and 1st-2nd fork rod (2) and then install retaining pin ( ) to 1st-2nd shift fork using a pin punch
[Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of 1st-2nd shift fork and
1st-2nd fork rod.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 1st-2nd shift fork.





10. Apply recommended grease to check balls (1) and then install its to adapter plate.

A : View from transmission rear side


CAUTION:
Never drop check ball.





11. Install 3rd-4th fork rod bracket (1) and 3rd-4th fork rod (2) and then install retaining pin ( ) to 3rd-4th fork rod bracket using a pin punch [Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of 3rd-4th fork rod bracket.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 3rd-4th fork rod bracket.





- Be careful with the orientation of 3rd-4th fork rod.

White arrow: Transmission front
A : View from transmission top side





12. Install 3rd-4th shift fork (1) and 3rd-4th fork rod (reversal side)
(2) and then install retaining pin ( ) to 3rd-4th shift fork using a pin punch [Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of 3rd-4th shift fork.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 3rd-4th shift fork.





- Be careful with the orientation of 3rd-4th fork rod (reversal side).

White arrow: Transmission front
A : Short
B : Long





13. Install 3rd-4th control lever (1) and shifter cap (2) to adapter plate and then tighten mounting bolts to the specified torque.

CAUTION:
- Be careful with the orientation of 3rd-4th control lever.
- Never lose shifter cap.





14. Install striking lever (1) and striking rod (2) and then install retaining pin ( ) to striking lever using a pin punch [Commercial service tool].

CAUTION:
- Never reuse retaining pin.
- Be careful with the orientation of striking lever and striking rod.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of striking lever.





15. Apply gear oil to check balls (1) and then install check balls and check ball springs (2) to adapter plate.

CAUTION:
Never drop check ball.
16. Apply recommended sealant to threads of check ball plugs (3) and then tighten its to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Fluid Type Specifications.

CAUTION:
Remove old sealant and oil adhering to threads.
17. Install baffle plate with the following procedure.





a. Insert baffle plate (1) until its projection contacts groove (A) of oil gutter (2).





b. Align baffle plate hole to adapter plate dowel pin ( ).





c. Install mounting bolt ( ) to adapter plate and then tighten mounting bolt to the specified torque.
18. Remove adapter plate assembly from vise.

CAUTION:
Never damage baffle plate.
19. Remove adapter setting plate [SST: ST22490000 ( - )] from adapter plate.

CASE AND EXTENSION





1. Install breather tube (1) to transmission case.

Dimension "L" : 2 mm (0.08 in) or less

CAUTION:
Never bend breather tube.
2. Install transmission case with the following procedure.





a. Install counter front bearing (1) to transmission case.
b. Apply recommended grease to roller of counter front bearing.





c. Apply recommended sealant to mating surface of transmission case as shown in the figure.

A : Start and finish point shall be in the center of two bolts

Dimension "B" : 3 - 5 mm (0.12 - 0.20 in)
Sealant width "C" : 1 - 2 mm (0.04 - 0.08 in)
Sealant height "C" : 0.4 - 1 mm (0.016 - 0.04 in)

- Use Genuine Silicone RTV or an equivalent. Fluid Type Specifications.

CAUTION:
- Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to both mounting surfaces.
- Apply sealant so as not to break the bead.
d. Install magnet to adapter plate.





e. Install transmission case to adapter plate.

CAUTION:
- Check for baffle plate weld bolt location while installing.
- Check that magnet is within the specified area of adapter plate while installing.
- Never drop counter front bearing.

NOTE:
Apply grease to magnet if it is difficult to keep magnet within the specified area of adapter plate.





f. Install snap ring to main drive gear bearing using snap ring pliers.

CAUTION:
Never reuse snap ring.
3. Install baffle plate with the following procedure.





a. Tighten baffle plate mounting nut ( ) to the specified torque.





b. Install mounting bolt ( ) to adapter plate and then tighten mounting bolt to the specified torque.
4. Install front cover with the following procedure.





a. Install front 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 incline front oil seal.
b. Install front cover gasket and front cover to transmission case.

CAUTION:
- Never reuse front cover gasket.
- Never damage front oil seal.
- Remove any moisture, oil, or foreign material adhering to both mating surfaces.





c. Temporarily tighten mounting bolt ( ) and sealing bolt (1).





d. Temporarily tighten mounting bolts ( ) and sealing bolts (1).





e. Tighten mounting bolts ( ) and sealing bolts (1) to the specified torque in the numerical order as shown in the figure.





5. Install reverse idler shaft assembly ( ) to adapter plate.
6. Install rear extension with the following procedure.
a. Install oil gutter with the following procedure.
i. Seat the prong of oil gutter in the groove on cap.





ii. Install oil gutter (1) to rear extension and then tighten mounting bolt to the specified torque.





b. Install striking rod oil seal to rear extension using the drift [SST:
ST33061000 (J-8107-2)].

CAUTION:
- Never reuse striking rod oil seal.
- Never incline striking rod oil seal.
c. Install dust cover to rear extension.





d. 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:
Never incline rear oil seal.





e. Apply recommended sealant to mating surface of rear extension as shown in the figure.

A : Start and finish point shall be in the center of two bolts.

Dimension "B" : 3 - 5 mm (0.12 - 0.20 in)
Sealant width "C" : 1 - 2 mm (0.04 - 0.08 in)
Sealant height "C" : 0.4 - 1 mm (0.016 - 0.04 in)

- Use Genuine Silicone RTV or an equivalent. Fluid Type Specifications.

CAUTION:
- Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to both mounting surfaces.
- Apply sealant so as not to break the bead.





f. Install rear extension to adapter plate and then tighten mounting bolts ( ) to the specified torque in the numerical order as shown in the figure.

CAUTION:
Never damage rear oil seal and striking rod oil seal.
7. 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.
8. Install return spring plug with the following procedure.





a. Apply gear oil to return spring plungers (1).
b. Install return spring plungers and return springs (2) to rear extension.






CAUTION:
The right and left return springs and return spring plungers are different, so make sure they are installed correctly.
c. Apply recommended sealant to threads of return spring plugs (3) and then tighten its to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Fluid Type Specifications.

CAUTION:
Remove old sealant and oil adhering to threads.





9. Install control bracket to rear extension and then tighten mounting bolts ( ) to the specified torque.
10. Install park/neutral position (PNP) switch with the following procedure.
a. Install plunger to rear extension.

CAUTION:





Be careful with orientation of plunger.

White arrow: Park/Neutral position (PNP) switch side





b. Temporarily tighten park/neutral position (PNP) switch onto rear extension by rotating once or twice.

CAUTION:
Remove old sealant and oil adhering to threads.
c. Apply recommended sealant to threads of park/neutral position
(PNP) switch as shown in the figure.
- Use Genuine Silicone RTV or an equivalent. Fluid Type Specifications.
d. Tighten park/neutral position (PNP) switch to the specified torque.
11. Install back-up lamp switch with the following procedure.





a. Temporarily tighten back-up lamp switch onto rear extension by rotating once or twice.

CAUTION:
Remove old sealant and oil adhering to threads.
b. Apply recommended sealant to threads of back-up lamp switch as shown in the figure.
- Use Genuine Silicone RTV or an equivalent. Fluid Type Specifications.
c. Tighten back-up lamp switch to the specified torque.
12. Install control rod with the following procedure.
a. Install boot to striking rod oil seal and then install control rod to striking rod.

CAUTION:





- Be careful with the orientation of control rod.

White arrow: Transmission front
A : View from transmission top side





- Be careful with the orientation of boot (1).

White arrow: Transmission front
2 : Striking rod oil seal





b. Install retaining pin ( ) to control rod using a pin punch [Commercial service tool].

1 : Boot


CAUTION:
- Never reuse retaining pin.
- Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of control rod.
c. Install boot to control rod.

CAUTION:





- Be careful with the orientation of boot.

A : View from transmission rear side

- Fit control rod boot to the groove on control rod.
d. Install control rod boot to control rod.

CAUTION:
Fit control rod boot to the groove on control rod.
13. Install brackets with the following procedure.





a. Install bracket (1) so that it contacts transmission case rib (A) and then tighten mounting bolt to the specified torque.

CAUTION:
Be careful with orientation of bracket.
b. Install bracket (2) so that it contacts rear extension side (B) and then tighten mounting bolt to the specified torque.
c. Install bracket (3) to rear extension and then tighten mounting bolts to the specified torque.
d. Install bracket (4) so that it contacts the projection (C) of rear extension and then tighten mounting bolt to the specified torque.
e. Install bracket (5) to rear extension and then tighten mounting bolt to the specified torque.





f. Install bracket (1) so that it contacts rear extension side (A) and then tighten mounting bolt to the specified torque.
g. Install bracket (2) to rear extension and then tighten mounting bolts to the specified torque.
14. Install rear extension upper cover with the following procedure.
a. Apply gear oil to check ball.

CAUTION:
Never drop check ball.





b. Install check ball and check select spring to rear extension.
c. Install rear extension upper cover gasket and rear extension upper cover to rear extension.

CAUTION:
- Never reuse rear extension upper cover gasket.
- Remove any moisture, oil, or foreign material adhering to both mating surfaces.
d. Temporarily tighten rear extension upper cover mounting bolts while holding rear extension upper cover.

CAUTION:
Avoid tangling check select spring.





e. Tighten mounting bolts ( ) to the specified torque in the numerical order as shown in the figure.
15. Install drain plug with the following procedure.
a. Install gasket to drain plug and then install it to transmission case.

CAUTION:
Never reuse gasket.
b. Tighten drain plug to the specified torque.
16. Install filler plug with the following procedure.
a. Install gasket to filler plug and then install it to transmission case.

CAUTION:
Never reuse gasket.
b. Tighten filler plug to the specified torque.

CAUTION:
After gear oil is filled, tighten filler plug to the specified torque.