Transmission Reassembly
Transmission ReassemblyNOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply manual transmission fluid (MTF) to all contact surfaces.
1. Press the new dust seal (A) into the transmission housing surface, then install the change lever (B), shift arm (C), 8 mm spring washer (D), and 8 mm special bolt (E).
2. Select the proper size 82 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install it into the transmission housing (B).
3. Install the oil pump outer rotor (A), oil pump inner rotor (B), and oil pump plate (C).
4. Install the differential assembly (A) and oil pump shaft (B).
5. Install the 64 mm spring washer (A). Note the installation direction of the 64 mm spring washer.
6. Apply tape to the mainshaft splines (B) to protect the seal. Install the mainshaft and countershaft (C) into the shift fork assembly (D) as an assembly.
7. Press the new dust seal (A) into the clutch housing surface, then install the select lever (B), select arm (C), new 5 mm spring pin (D), and new 3 mm spring pin (E).
8. Set the select return spring (A), 8 x 50 mm pin (B), and interlock (C) as shown.
9. Install the shift piece (A) and shift piece shaft (B).
10. Install the 33 mm spring washer (A). Note the installation direction of the spring washer.
11. Install the 20 mm thrust needle bearings (B), 20 mm thrust washers (C), reverse idler gear shaft assembly (D), and reverse shift fork (E) as an assembly.
12. Slide the reverse idler gear shaft assembly (A) on the rib (B) of the clutch housing, then install it into the hole (C) of the clutch housing.
13. Install the reverse shift lever (A), and 8 x 50 mm pin (B).
14. Install the oil guide pipe A, oil guide pipe B, and magnet (C).
15. Clean any dirt and oil from the transmission housing sealing surface.
16. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the transmission housing and the clutch housing. Install the component within5 minutes of applying the liquid gasket.
NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
17. Install the three 14 x 20 mm dowel pins (A).
18. Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).
19. While expanding the 75 mm snap ring (E) of the countershaft ball bearing with snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Then release the pliers, and push down the housing unit it bottoms and the snap ring snaps in place in the counter shaft ball bearing snap ring groove.
20. Make sure the 75 mm snap ring is securely seated in the groove of the countershaft bearing.
21. Install the new 37.7 mm O-ring (F) and transmission case cap (G).
NOTE: Check the operation of the change lever and select lever.
22. Install transmission hanger A, transmission hanger B, 8 mm flange bolt (C), and the 10 mm flange bolts, finger-tight.
23. Tighten the 10 mm flange bolts in a crisscross pattern in several steps.
24. Install the oil check bolt (A), new 6 mm washer (B), drain plug (C), and new 14 mm washer (D).
25. Apply liquid gasket, P/N 08718-0001 evenly to the set screws (A), then install the set screws, 22.0 mm spring (B), 27.4 mm spring (C), steel balls (D), input shaft (mainshaft) speed sensor (E), output shaft (countershaft) speed sensor (F), and new O-rings (G). Install the component within 5 minutes of applying the liquid gasket.
NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
26. Apply liquid gasket, P/N 08718-0001 evenly to the set screws (A), then install the set screws, 22.0 mm spring (B), 26.1 mm spring (C), 27.4 mm springs (D), steel balls (E), 20.0 mm washer (F), and clutch line bracket (G). Install the filler plug (H) finger-tight. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
27. Clean any dirt or oil from the reverse lockout solenoid sealing surface.
28. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the reverse lockout solenoid and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
29. Install the transmission harness bracket (A) and the reverse lockout solenoid (B).
30. Apply liquid gasket, P/N 08718-0001 evenly to the threads of the back-up light switch (C), and install the switch in the transmission housing. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
31. Install the strainer cover (A), new O-ring (B), strainer set spring (C), and oil pump strainer (D).
32. Adjust the differential carrier bearing preload.