Assembly
1. Assemble front case.
a. Install main gear assembly by tapping lightly.
b. Apply sealant to the mating surface and bolts of front case cover and install it on front case. These ten bolts should be coated with sealant.
Tightening torque:
Bolts A: 16 - 21 Nm (12 - 15 ft. lbs.)
Bolts B: 19 - 24 Nm (14 - 17 ft. lbs.)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly.
e. Install cross shaft and inner shift lever. When replacing cross shaft, outer shift lever or lock pin of outer shift lever, replace them as a set.
f. Apply sealant to plug and install it into front case.
g. Insert interlock plunger into front case.
h. Install L & H shift rod and fork assembly with coupling sleeve.
i. Install 2-4 shift rod.
j. Install switches, check balls, check springs and plugs. Apply sealant to switches and plugs.
2. Select counter gear rear bearing shim.
a. Seat counter gear assembly.
b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case and allow gauging cylinder to rest on top outer portion of counter gear rear bearing.Lock gauging cylinder in place.
c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder).
d. Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, and allow gauging plunger to drop until it contacts counter gear rear bearing mating surface.
e. Lock gauging plunger in place and use feeler gauge to measure gap between gauging cylinder and gauging plunger.
f. Use measured distance and following chart to select correct shim.
Counter gear end play: 0 - 0.2 mm(0 - 0.008 inch)
g. Select counter gear rear bearing shim.
3. Place suitable shim on counter gear rear bearing with grease.
4. Apply gear oil to each part in front case.
5. Assemble center case assembly.
a. Install mainshaft on center case by tapping lightly. Apply gear oil to mainshaft front bearing.
b. Install bearing retainer and tighten to 16 - 21 Nm (12 - 15 ft. lbs.)
c. Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case. Be sure to install drive chain in the same direction as removed.
d. Install front drive shaft by tapping lightly. Make sure shafts are lined up in the case.
e. Apply gear oil to needle bearings and install them into front drive sprocket. These needle bearings will be installed move easily if front drive sprocket is rotated while installing them.
f. Install 2-4 coupling sleeve with 2-4 shift fork. Pay special attention to direction of coupling sleeve.
g. Install shifting inserts and spread spring. Pay special attention to direction of shifting inserts.
h. Install baulk ring, then install clutch gear and mainshaft rear bearing. Install spacer.
i. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 inch)
j. Install steel ball, speedometer drive gear and retainer ring. Steel ball is the smallest of check balls for this unit.
k. Install low gear and its bearing to mainshaft. Apply gear oil to needle bearing.
l. Install L & H hub and snap ring to mainshaft. Pay special attention to direction of L & H hub.
m. Measure end play of low gear.
Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 inch)
6. Apply sealant to mating surface and put center case assembly onto front case and tighten bolts.
7. Install snap ring to 2-4 shift rod.
8. Install oil gutter and oil cover.
9. Apply gear oil to each part in center case.
10. Apply sealant to mating surface and install rear case on center case.
11. Install 4WD switch. Apply sealant to thread of switch.