Part 3

TRANSMISSION
Reassembly





1. Install the oil seal, shift arm, and shift lever in the transmission housing.





2. Install the shift detent spring and spring set plate.





3. Install the oil seal, select arm, and select lever in the clutch housing.





4. Install the differential assembly into the clutch housing.





5. Install the spring washer, then insert the mainshaft and countershaft into the shift forks and install them as an assembly. Tape the mainshaft splines before installation.





6. Install the change holder assembly in the clutch housing. Place the interlock finger in the groove of the select arm.





7. Install the reverse idle gear shaft assembly.





8. Shift the reverse synchro sleeve to the driven gear side, then install the reverse shift fork assembly.





9. Install the reverse shift arm.





10. Apply liquid gasket to the surface of the transmission housing mating with the clutch housing as shown, and note those items:
- Use liquid gasket (P/N 08718-0001).
- Remove any dirt or oil from the sealing surface.
- Seal the entire circumference of the bolt holes to prevent oil leakage.
- If 20 minutes have passed after applying liquid gasket, reapply it and assemble the housings.
- After assembly, wait at least 30 minutes before refilling with oil.
11. Install the dowel pins on the clutch housing.





12. Place the transmission housing over the clutch housing, being careful to line up the shafts.





a. Place the shift lever as a shown.





b. Lower the transmission housing, then place the shift arm in the groove of the shift piece by turning the shift lever.





c. Check the operation of the shift lever.





13. Lower the transmission housing with snap ring pliers, and set the snap ring in the groove of the countershaft bearing.





14. Check that the snap ring is securely seated in the groove of the countershaft bearing.

Dimension A as installed: 1.37 - 7.85 mm (0-054 - 0.309 inch)





15. Tighten the transmission housing attaching bolts in a crisscross pattern in several steps as shown below.
16. Apply liquid gasket (P/N 08718-0001) to the threads, and install the 36 mm sealing bolt.
17. Install the steel balls, springs, and sealing bolts.

NOTE: Apply liquid gasket (P/N 08718-0001) to the threads, but don't plug the hole with liquid gasket.





18. Apply liquid gasket (P/N 08718-0001) to the threads, and install the back-up light switch and neutral position switch.

A: 8 x 1.25 mm 24 Nm (2.4 kgf-m, 17 ft. lbs.)
B: 8 x 1.25 mm 25 Nm (2.6 kgf-m, 19 ft. lbs.)
C: 6 x 1.0 mm 12 Nm (1.2 kg/m; 9 ft. lbs.)
D: 6 x 1.0 mm 14 Nm (1.4 kgf-m, 10 ft. lbs.)

19. Install the differential speed sensor, reverse lockout solenoid, and Vehicle Speed Sensor (VSS).