5TH/Reverse Gear and Housing Parts Assembly

Part 1 Of 2:

Part 2 Of 2:

NOTE: Assemble in the order shown, Refering to the following Assembly Notes.

PRIMARY SHAFT ASSEMBLY AND SECONDARY SHAFT ASSEMBLY





1. Install the primary shaft assembly and the secondary shaft assembly together.

SHIFT FORK AND SHIFT ROD ASSEMBLY





1. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.





2. Insert the spring seat and spring into the reverse lever shaft. Install the steel ball, and place a scraper so that it contacts the steel ball.





3. Pushing the control end upward moves the ball into the shaft and aligns the edges of the scraper and the control end. This action will also align the shift rod coupling hole in the clutch housing.
4. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove (of the 3 grooves in the control end).
5. Pull the ball part of the control end forward so that the steel ball goes into the groove's detent.

CRANK LEVER ASSEMBLY AND CRANK LEVER SHAFT

NOTICE: Use a new O-ring for the crank lever shaft.

1. Fit the crank lever between the change arm and the control end, and connect the crank lever shaft to the crank lever.





2. Align the pin holes of the crank lever shaft and the clutch housing, and insert the new pin.

5TH SHIFT ROD END AND 5TH SHIFT ROD

NOTICE: The mark (indicated by the arrow) and the shift rod end mounting bolt hole must be in the same direction.





1. Install the shift rod end (1) and the shift rod (2). Tighten the mounting bolt.

REVERSE IDLER GEAR AND REVERSE IDLER SHAFT
1. Install the reverse idler gear and the reverse idler shaft.
2. Attach the magnet to the clutch housing.





3. Align the end of the interlock sleeve with the control lever (indicated by the arrow). At the same time, align the reverse idler shaft with the alignment mark on the clutch cover flange.

TRANSAXLE CASE ASSEMBLY





1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case. Tighten the transaxle case installation bolts to the specified torque.

Tightening torque: 29 - 40 ft. lbs. (39 - 54 Nm)

PRIMARY AND SECONDARY 5TH GEARS





1. Install the primary and secondary 5th gears as shown.

5TH/REVERSE CLUTCH HUB ASSEMBLY AND 5TH/REVERSE SHIFT FORK
1. Install the clutch hub assembly (5th/Reverse) and the 5th/Reverse shift fork together.

LOCKNUT
1. Shift to 1st gear.





2. Lock the primary shaft with the SST (or equivalent).
3. Tighten new locknuts on the primary and secondary shafts.

Tightening torque: 98 - 158 ft. lbs. (133 - 214 Nm)





4. Measure the primary synchronizer gear and 5th gear thrust clearance by using a dial indicator.

Primary Reverse Synchronizer Gear and 5th Gear:
Clearance: 0.0032 - 0.0078 inch (0.080 - 0.200 mm)
Maximum: 0.250 inch (0.0098 mm)

5th Gear:
Clearance: 0.0037 - 0.0085 inch (0.095 - 0.215 mm)
Maximum: 0.0106 inch (0.270 mm)

5. If clearances are as specified, reassemble the transaxle.
6. After verifying clearances, stake the locknut.