Assembly

Assembly





1. Using a drift, install input shaft oil seal from clutch housing end of side to the depth of 1.8 to 2.8 mm (0.071 to 0.110 inch).

CAUTION: Do not reuse oil seal.





2. Using a drift, install differential oil seal until the face is flush with clutch housing.

CAUTION: Do not reuse oil seal.





3. Install oil channel on mainshaft side.

CAUTION: Be careful with orientation of installation.





4. Using a drift, install mainshaft front bearing.

CAUTION: Be careful with orientation of installation.





5. Install bearing retainer.

CAUTION: Install with punched surface facing up.





6. Install differential side bearing outer race.





7. Install final drive assembly into clutch housing.





8. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.

CAUTION: Be sure not to damage input shaft oil seal.





9. Install 1 et-2nd fork rod bracket onto 1st-2nd fork rod, and then install retaining pin.

CAUTION: Do not reuse retaining pin.





10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install retaining pin.

CAUTION: Do not reuse retaining pin.

11. Install shift check sleeve.





12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with inter lock pin.
13. Install stopper ring onto 3rd-4th shift fork.

CAUTION: Do not reuse stopper ring.

14. Install retaining pin onto 3rd-4th bracket.

CAUTION: Do not reuse retaining pin.

15. Install 2 check balls.





16. Install 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod with inter lock pin.
17. Install stopper ring onto 5th-6th bracket.

CAUTION: Do not reuse stopper ring.





18. Install retaining pin onto 5th-6th shift fork.

CAUTION: Do not reuse retaining pin.
19. Install 2 check balls.
20. Install reverse bracket fork rod and reverse lever bracket.
21. Install retaining pin onto reverse bracket.

CAUTION: Do not reuse retaining pin.

22. Install reverse shift fork and reverse fork rod.
23. Install reverse lever assembly following procedures below.





a. Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork.

CAUTION: Do not drop shifter cap.





b. While lifting reverse shift fork, align cam with reverse bracket.





c. Tighten mounting bolts to specified torque, and then install reverse lever assembly.
24. Install the magnet onto clutch housing.
25. Using a drift, install differential oil seal until it is flush with end face of transaxle case.

CAUTION: Do not reuse oil seal.

26. Install selected input shaft adjusting shim onto input shaft.
27. Install baffle plate and oil gutter.
28. Install transaxle case following procedures below.





a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
b. Temporarily install snap ring of mainshaft rear bearing into transaxle case.

CAUTION: Do not reuse the snap ring.





c. Apply Anaerobic Liquid Gasket or equivalent to mating surfaces of transaxle case and clutch housing.

CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.





d. With snap ring of mainshaft rear bearing temporarily installed, place transaxle case over clutch housing.





e. Through bore plug mounting hole, with snap ring stretched, and lift up mainshaft assembly from the control assembly mounting hole.
f. Securely install snap ring onto mainshaft rear bearing.





g. Tighten mounting bolts.
Bolt A: 50.0 - 53.9 Nm (5.1 - 5.4 kgf-cm, 37 - 39 ft. lbs.)
Bolt B: 63.0 - 66.9 Nm (6.5 - 6.8 kgf-cm, 47 - 49 ft. lbs.)

CAUTION: Always replace bolts B as they are self-sealing bolts.

h. Install control assembly.

CAUTION: Do not reuse the O-ring.

i. Install shift check and stopper bolt.

CAUTION: Do not reuse shift check and stopper bolt.





29. Using a drift, install bore plug.

CAUTION: Do not reuse bore plug.





30. Using a drift, install Welch plug.

CAUTION: Do not reuse Welch plug.





31. Install 2 shift check sleeves, 4 check balls, 4 check springs, and 4 check ball plugs.

CAUTION: Do not reuse check ball plug.





32. Apply Anaerobic Liquid Gasket or equivalent to threads of neutral switch and reverse lamp switch. Then install them into transaxle case.
33. Install gaskets onto drain plug and filler plug, and then install them into transaxle case.

CAUTION:
- Do not reuse gasket.
- After oil is filled, tighten filler plug to specified torque.