Part 1
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. Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.
b.Install bearing retainer to adapter plate and then tighten mounting bolts (black arrow) 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.
- 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 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 (black arrow) with synchronizer hub groove when assembling.
8.Install reverse synchronizer hub assembly (1) with the following procedure.
a.Set the press plate (A) [SST: KV-32103300 (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: ST-01530000 ( - )].
CAUTION:
Be careful with the orientation of reverse coupling sleeve.
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.
End play "L": 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.
- 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: ST-23860000 ( - )].
CAUTION:
- Never reuse reverse counter gear.
- Be careful with the orientation of reverse counter gear.
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.
End play "L": 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 (black arrow) 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 (black arrow) 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.
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 (black arrow) 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.
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 (black arrow) 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.
CAUTION:
Never drop check ball.
11.Install 3rd-4th fork rod bracket (1) and 3rd-4th fork rod (2) and then install retaining pin (black arrow) 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.
12.Install 3rd-4th shift fork (1) and 3rd-4th fork rod (reversal side)
(2) and then install retaining pin (black arrow) 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).
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 (black arrow) 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. Recommended Chemical Products and Sealants.
CAUTION:
Remove old sealant and oil adhering to threads.