Before VIN #343314
Gear Components
1. Install bearings into case components.
2. Assemble adapter plate parts.
- Install oil gutter on adapter plate and expand on rear side.
- Install bearing retainer.
a. Insert reverse idler shaft, then install bearing retainer.
b. Tighten each screw, then stake each one at two points.
3. Install main drive gear ball bearing.
a. Press main drive gear ball bearing.
b. Select and install proper main drive gear snap ring to achieve proper clearance of groove.
Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 inch)
Main drive gear bearing snap ring: Refer to Application and ID.
Application and ID
4. Assemble synchronizers.
- 1st and 2nd (2WD model) synchronizer
- Check coupling sleeve and synchronizer hub orientation.
- 2nd double baulk ring type synchronizer (4WD model)
- 3rd & 4th synchronizer
- The three synchronizer gutters should be at the rear.
- Overdrive & reverse synchronizer
5. Assemble front side components to mainshaft.
a. Install 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly; then press 1st gear bushing on mainshaft.
b. Install 1st main gear.
c. Install steel ball and 1st gear washer.
- Before installation, apply multi-purpose grease to steel ball and to both sides of the 1st gear washer.
6. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft as follows:
a. Press mainshaft assembly into adapter plate using Tool.
b. Press counter gear into adapter plate using Tool.
c. Install 3rd main gear and needle bearing, then press 3rd & 4th synchronizer assembly onto mainshaft.
- Pay attention to the direction of 3rd & 4th synchronizer.
d. Install front mainshaft snap ring.
Select proper front mainshaft snap ring to achieve proper clearance of groove.
Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 inch)
Mainshaft front snap ring: Refer to Application and ID.
Application and ID
e. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.
f. Press counter drive gear together with main drive gear using Tool.
- Pay attention to the direction of counter drive gear.
g. Install sub-gear components.
1. Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring that will minimize clearance of groove in counter gear.
^ Do not install sub-gear spring at this time.
Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 inch)
Counter drive gear snap ring: Refer to Application and ID.
2. Remove snap ring, sub-gear bracket and sub-gear from counter gear.
3. Reinstall sub-gear, sub-gear spring, sub-gear bracket and snap ring.
h. Press counter/gear front bearing onto counter gear using Tool.
7. Install rear side components on mainshaft and counter gear as follows:
a. Install sub-gear parts (sub-gear, sub-gear spring, sub-gear bracket, steel ball and snap ring) on the reverse idler gear.
b. Install reverse idler gear to reverse idler shaft along with reverse idler thrust washer, snap rings and reverse idler gear bearing.
c. Install bushing, reverse main gear and overdrive & reverse synchronizer to mainshaft.
- Pay attention to the direction of synchronizer hub.
d. Install overdrive gear bushing to mainshaft using Tool.
e. Install overdrive main gear and needle bearing to mainshaft.
f. Install spacer, reverse counter gear and overdrive counter gear to counter/gear.
- OD main gear and OD counter gear should be handled as a matched set.
g. Install washer, roller bearing, steel roller and thrust washer.
h. Tighten mainshaft lock nut temporarily.
- Always use new lock nut.
i. Install counter/gear rear end bearing using Tool.
8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut using Tool.
- Always use new lock nut.
Mainshaft lock nut: 137 - 167 Nm (14.0 - 17.0 kg-m, 101 - 123 ft. lbs.)
- Use the chart shown to determine the proper reading torque.
(Length of torque wrench vs. setting or reading torque) Reference: Formula to convert torque wrench indication to the true torque value: T = 0.1 m (0.33 ft.) + L/L x C
If the specified torque is T kg-m (ft. lbs.), the torque wrench scale indication C is determined using the following formula.
C = T x L/0.1 m (0.33 ft.) + L
9. Tighten counter gear lock nut.
- Always use new lock nut.
Counter gear lock nut: 98 - 127 Nm (10.0 - 13.0 kg-m, 72 - 94 ft. lbs.)
10. Stake mainshaft lock nut and counter gear lock nut using a punch.
11. Measure gear end play. Refer to Disassembly. Disassembly
12. Install snap ring and OD mainshaft bearing, then snap ring (2WD model only).
Allowable clearance: 0 - 0.14 mm (0 - 0.0055 inch)
OD mainshaft bearing snap ring: Refer to Application and ID.
Shift Control Components
1. Install fork rods, interlock plunger, interlock balls and check balls.
2. Install 1st & 2nd shift fork, then drive in retaining pin.
3. Install 3rd & 4th shift fork, then drive in retaining pin.
4. Install overdrive & reverse shift fork, then drive in retaining pin.
Case Components
1. Install front cover oil seal using Tool.
- Apply multi-purpose grease to seal lip.
2. Apply sealant to mating surface of transmission case as shown in the figure.
- Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
3. Slide gear assembly onto adapter plate by lightly tapping it using a soft hammer.
4. Install main drive gear ball bearing snap ring.
5. Apply sealant to mating surface of adapter plate as shown.
- Use genuine anaerobic liquid gasket Three Bond TB1215, Loctite Part No. 51813 or equivalent.
6. Place shift forks in neutral position.
7. Install striking lever and rod onto adapter plate and align striking lever with shift brackets.
8. Install rear extension.
- Tighten mounting bolts equally in a criss-cross pattern.
9. Install striking lever retaining pin.
10. Select counter gear front bearing shim.
Allowable clearance (A) from bearing surface to transmission case: 0 - 0.16 mm (0 - 0.0063 inch)
Countershaft front bearing shim: Refer to Application and ID.
11. Install gasket and front cover.
12. Install check ball, return springs, select check plungers and plugs.
13. Install control housing and gasket.