Part 2

10. Press on mainshaft rear bearing.





11. Press on mainshaft front bearing.
12. Measure gear end play as the final check.

FINAL DRIVE
DISASSEMBLY





1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
- Be careful not to mix up the right and left bearings.





4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.

INSPECTION
Gear, Washer, Shaft and Case





- Check mating surfaces of differential case, side gears and pinion mate gears.
- Check washers for wear.

Bearing





- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.

ASSEMBLY





1. Attach side gear thrust washers to side gears and install in differential case.
2. Install pinion mate washers and pinion mate gears.





3. Insert pinion mate shaft.
- When inserting, be careful not to damage pinion mate thrust washers.





4. Measure clearance between side gear and differential case with washers following the procedure below:
a. Set Tool and dial indicator on side gear.





b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears.

Clearance between side gear and differential case with washers: 0.1 - 0.2 Nm (0.004 - 0.008 inch) or less

c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.





Side gear thrust washer: Refer to image.





5. Install retaining pin.
- Make sure that retaining pin is flush with case.





6. Install final gear.
- Apply locking sealant to final gear fixing bolts before installing them.
7. Install speedometer drive gear and stopper.





8. Press on differential side bearings.

SHIFT CONTROL COMPONENTS
INSPECTION





- Check contact surface and sliding surface for wear, scratches, projections or other damage.

CASE COMPONENTS
Input Shaft Oil Seal





1. Drive out input shaft oil seal.





2. Install input shaft oil seal.
- Apply multi-purpose grease to seal lip of oil seal before installing.

Input Shaft Rear Bearing





1. Remove welch plug from transmission case.





2. Remove input shaft rear bearing by tapping it from welch plug hole.





3. Install welch plug.
- Apply recommended sealant to mating surface of transmission case.





4. Install input shaft rear bearing.

Mainshaft Front Bearing Outer Race And Oil Channel





1. Remove mainshaft front bearing outer race.
2. Remove oil channel.





3. Install oil channel.
- Ensure that the oil groove faces the oil pocket.





4. Install mainshaft front bearing outer race.

Differential side bearing outer race
- Refer to Differential Side Bearing Preload.
Mainshaft rear bearing outer race
- Refer to Mainshaft Bearing Preload.

ADJUSTMENT
DIFFERENTIAL SIDE BEARING PRELOAD
If any of the following parts are replaced, adjust differential side bearing preload.
- Differential case
- Differential side bearing
- Clutch housing
- Transmission case





1. Remove differential side bearing outer race (transmission case side) and shim(s).





2. Install differential side bearing outer race without shim(s).
3. Install final drive assembly on clutch housing.
4. Install transmission case on clutch housing.
- Tighten transmission case fixing bolts to the specified torque.





5. Set dial indicator on front end of differential case.
6. Insert Tool all the way into differential side gear.
7. Move Tool up and down and measure dial indicator deflection.
8. Select shim considering bearing preload.
- Suitable shim thickness = Dial indicator deflection + specified bearing preload





- Differential side bearing adjusting shims and preload: Refer to image.
9. Install selected shim(s) and differential side bearing outer race.
10. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
- Tighten transmission case fixing bolts to the specified torque.





c. Measure turning torque of final drive assembly.

Turning torque of final drive assembly (New bearing): 2.0 - 7.8 Nm (20 - 80 kg.cm, 17 - 69 inch lbs.)

- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.
- Changes in turning torque of final drive assembly per revolution should be within 1.0 Nm (10 kg.cm, 8.7 inch lbs.) without binding.

MAINSHAFT BEARING PRELOAD
If any of the following parts are replaced, adjust mainshaft bearing preload.
- Mainshaft
- Mainshaft bearings
- Clutch housing
- Transmission case





1. Remove case cover, O-ring, mainshaft bearing adjusting shim, spacer and mainshaft rear bearing outer race from transmission case.
2. Install mainshaft assembly on clutch housing.
3. Install transmission case on clutch housing.
- Tighten transmission case fixing bolts to the specified torque.





4. Install mainshaft rear bearing outer race on inner race.





5. Measure distance from transmission case to bearing outer race.
- Make sure that bearing is properly seated.





6. Select shim. Refer to image.
7. Check total turning torque after assembling.

ASSEMBLY





1. Install striking rod, lever and interlock.
- Tape edges of striking rod to avoid damaging oil seal lip during installation. When taped edges of striking rod are past the oil seal, remove tape.





2. Install reverse check sleeve assembly.
3. Install check balls, reverse check spring and check plug.





4. Check reverse check turning torque (At striking rod).





Reverse check turning torque (At striking rod): Refer to image.

- If not within specification, select another check plug having a different length and reinstall it.





Reverse check plug: Refer to image.

5. Install selected reverse check plug.
- Apply locking sealant to thread of plug before installing it.





6. Install check ball plug, shift check ball and shift check spring.
7. Install oil pocket.





8. Install gear components onto clutch housing.
a. Install input shaft assembly and reverse idler gear.
- Be careful not to damage oil seal lip with splines of input shaft.





b. Install final drive assembly.
c. Install mainshaft assembly.
- Take care not to damage oil channel when inserting mainshaft into clutch housing.





9. Apply grease to shifter caps, then install it to control bracket. Install control bracket with 1st & 2nd shift fork.
10. Install 3rd & 4th and 5th shift forks.





11. Insert fork shaft.
- Apply multi-purpose grease to support spring before installing.

12. Install reverse idler spacer.





13. Apply recommended sealant to mating surface of clutch housing.
14. Install transmission case on clutch housing.





15. Measure total turning torque.

Total turning torque (New bearing): 3.9 - 13.7 Nm (40 - 140 kg.cm, 35 - 122 inch lbs.)

- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.