Assembly

Exploded View MT-19 (Part 1):

Exploded View MT-19 (Part 2):

Exploded View MT-20 (Part 1):

Exploded View MT-20 (Part 2):

Exploded View MT-20 (Part 3):

ASSEMBLY





1. Install pinion gear (1) and pinion shaft (2) into clutch housing.





2. Install two way connector (1) into clutch housing.





3. Install bushings (1) until they are flush with end face of clutch housing using a suitable tool (A).





4. Install oil channel and mainshaft front bearing outer race into clutch housing using Tool (A).
Tool number A: KV38100200 ( - )

CAUTION: Do not reuse oil channel.





5. Install input shaft oil seal (1) into clutch housing using Tool (A).
Tool number A: ST33220000 ( - )





6. Install snap ring (1) and oil channel (2) onto transaxle case.





7. Install bearing preloading shim and mainshaft rear bearing outer race into transaxle case using Tool (A).
Tool number A: KV38100200 ( - )





8. Install bushings (1) into transaxle case using a suitable tool (A).





9. Install oil gutter (1) onto transaxle case.





10. Install shift lever oil seal (1) into transaxle case using a suitable tool (A).

CAUTION: Do not reuse shift lever oil seal.

11. Install select lever oil seal and bushings into transaxle case using a suitable tool.





12. Install shift finger (1) into transaxle case.





13. Install select lever (1) and then install retaining pin.

CAUTION: Do not reuse retaining pin.





14. Install shim and differential side bearing outer race (transaxle case side) into transaxle case using Tool (A).
Tool number A: ST33400001 (J-26082)





15. Install differential side bearing outer race (clutch housing side) into clutch housing using Tool (A).
Tool number A: KV38100200 ( - )





16. Install differential side oil seals (1) into clutch housing and transaxle case using Tool (A).
Tool number A: KV38100300 (J-25523)
17. Install magnet onto clutch housing.
18. Install final drive assembly into clutch housing.





19. Install input shaft assembly (1), mainshaft assembly (2) and 1st-2nd fork rod assembly (3) into clutch housing.
20. Install spring washer located under the reverse idler shaft.





21. Install reverse gear assembly (1) according to the following.
a. Lift up the input shaft assembly (2) and mainshaft assembly (3).
b. Install reverse gear assembly (1) and reverse fork rod (4) to clutch housing.





22. While lifting up fork rod (1), install 3rd-4th and 5th-6th fork rod assembly to clutch housing.





23. Install retaining pin into 5th-6th shift fork using a suitable tool.

CAUTION: Do not reuse retaining pin.





24. Move 1st-2nd fork rod (1), 3rd-4th and 5th-6th fork rod assembly (2), and reverse fork rod (3) to neutral position.
25. Install selector (4) into clutch housing.
26. Install spring of selector into return bushing.
27. Apply recommended sealant onto the mating surface of transaxle case.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-44, "Recommended Chemical Products and Sealants". Testing and Inspection

CAUTION:
^ Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.
^ Check for damage on the mating surface.
^ Apply a continuous bead of liquid gasket to the mating surface.





28. Engage shift finger and selector by moving select lever (1). Install transaxle case to clutch housing.





29. Install seal washer and reverse idler shaft bolt (<-), and then tighten bolt to specification. Refer to Exploded View MT-20.

CAUTION: Do not reuse seal washer.





30. Tighten bolts to specification. Refer to Exploded View MT-19.





31. Apply sealant to the threads of position switch (1). Then install it into transaxle case and tighten to specification. Refer to Exploded View MT-19.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-44, "Recommended Chemical Products and Sealants". Testing and Inspection
32. Install bracket (2), and tighten bolt to specification. Refer to Exploded View MT-19.
33. Install shift lever (3), and then install retaining pin using a suitable tool.

CAUTION: Do not reuse retaining pin.

34. Install CSC onto clutch housing. Refer to Exploded View MT-19.
35. Install a new gasket onto drain plug, and then install it into clutch housing using the socket. Tighten drain plug to specification. Refer to Exploded View MT-19.
36. Install a new gasket onto filler plug, and then install it into transaxle case. Tighten filler plug to specification. Refer to Exploded View MT-19.

CAUTION:
^ Do not reuse gasket.
^ After oil is filled, tighten filler plug to specification.