Part 2

TRANSMISSION ASSEMBLY

Assembly

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 (black arrow).





c.Install mounting bolt (black arrow) 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: ST-22490000 ( - )] from adapter plate.

CASE AND EXTENSION






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





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.









-Use Genuine Silicone RTV or an equivalent. 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.
- 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 (black arrow) to the specified torque.





b.Install mounting bolt (black arrow) 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:
KV-38102100 (J-25803-01)].





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 (black arrow) and sealing bolt (1).





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





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





5.Install reverse idler shaft assembly (black arrow) 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:
ST-33061000 (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:
ST-33400001 (J-26082)].





CAUTION:
Never incline rear oil seal.





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









-Use Genuine Silicone RTV or an equivalent. 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.
- Apply sealant so as not to break the bead.





f.Install rear extension to adapter plate and then tighten mounting bolts (black arrow) 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. Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant and oil adhering to threads.





9.Install control bracket to rear extension and then tighten mounting bolts (black arrow) 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.















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. Recommended Chemical Products and Sealants.
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. Recommended Chemical Products and Sealants.
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.










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










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






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.





- 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 (black arrow) 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.