Manual Transmission Reassembly

Manual Transmission Reassembly

NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

1. If any of the items listed were replaced, do the differential carrier bearing preload adjustment before reassembling the transmission Manual Transmission Disassembly.

- Transmission housing

- Clutch housing

- Differential carrier

- Spacer

- Differential carrier bearing and outer race

2. Press a new 16 x 23 x 5 mm dust seal (A) flush with the transmission housing surface, then install the change lever (B), the shift arm (C), the 8 mm spring washer (D), and the 8 mm special bolt (E).

NOTE: Be sure to install the spring washer in the direction shown.





3. Install the breather cap (F) with the arrow on the cap toward the front of the vehicle.

4. Select the proper size 87 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment M/T Main Shaft Thrust Clearance Adjustment. Install it into the transmission housing (B).






5. Install the oil pump outer rotor (A), the oil pump inner rotor (B), and the oil pump plate (C).






6. Install the oil gutter plate (A).






7. Install the transfer output shaft assembly (A).






8. Install the differential assembly (A) and the oil pump shaft (B).






9. Install the 64 mm spring washer (A).

NOTE: Be sure to install the spring washer in the direction shown.





10. Apply tape to the mainshaft splines (B) to protect the seal. Install the mainshaft and the countershaft (C) with the shift fork assembly (D) as an assembly.

NOTE: Do not apply tape thick to damage the oil seal.

11. Press a new 14 x 20 x 4 mm dust seal (A) flush with the clutch housing surface, then install the select lever (B), the select arm (C), a new 5 x 22 mm spring pin (D), and a new 3 x 22 mm spring pin (E).

NOTE: Make the seams (F) of the 5 x 22 mm and 3 x 22 mm spring pin are opposite side.






12. Set the select return spring (A), the 8 x 50 mm pin (B), and the interlock (C) as shown.






13. Install the shift piece (A) and the shift piece shaft (B).






14. Assemble the 25 mm thrust needle bearings (A), the 25 mm thrust washers (B), the reverse idler gear shaft assembly (C), and the reverse shift fork (D) M/T Reverse Idler Gear Shaft Assembly Disassembly/Reassembly.





15. Install the 36 mm spring washer (E) to the reverse idler gear shaft assembly.

NOTE: Be sure to install the spring washer in the direction shown.

16. 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.






17. Install the reverse shift lever (A) and the 8 x 50 mm pin (B).






18. Install oil guide pipe A, the oil guide pipe (B), and the magnet (C).

NOTE: Clean the magnet anytime the transmission is disassembled.





19. Clean any dirt and oil from the transmission housing sealing surface.

20. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the clutch housing mating surface of 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.





21. Install the three 14 x 20 mm dowel pins (A).









22. Lower the transmission housing, then place the shift arm (B) in the groove of the shift piece (C) by turning the change lever (D).

23. While expanding the 75 mm snap ring (E) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.

24. Make sure the 75 mm snap ring is securely seated in the groove of the countershaft bearing.





25. Install a new O-ring (F) and the transmission case cap (G).

NOTE: Check the operation of the change lever and the select lever.

26. Install the 10 mm flange bolts finger-tight, with transmission hanger B and the clutch line bracket (A).






27. Tighten the 10 mm flange bolts in a crisscross pattern in several steps.










28. Install the drain plug (A) with a new sealing washer (B).





29. Install the fluid check bolt (C) with a new sealing washer (D) by finger-tight.

30. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolts (A), then install the steel balls (B), the 22.0 mm detent ball spring (C), the 27.4 mm detent ball spring (D), and the detent bolts.





31. Install the input shaft (mainshaft) speed sensor (E), the output shaft (countershaft) speed sensor (F), and new O-rings (G).

32. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the thread of the detent bolts (A), then install the steel balls (B), the 22.0 mm detent ball spring (C), the 26.1 mm detent ball spring (D), the 27.4 mm detent ball spring (E), and the detent bolts.





33. Install the filler plug (F) with a new sealing washer (G) by finger-tight.

34. Clean any dirt or oil from the reverse lockout solenoid sealing surface.

35. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the transmission housing mating surface of the reverse lockout solenoid. 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.





36. Install the select lock pin spring (B), the select lock pin (C), and the reverse lockout solenoid (D).





37. Apply liquid gasket, (P/N 08717-0004, 08718-0001, 08718-0012, 08718-0003, 08718-0004, or 08718-0009) to the threads of the back-up light switch (E), and install it in the transmission housing.

38. Install transmission hanger A.

39. Install the oil pump strainer (A), the strainer set spring (B), and the strainer cover (C) with a new O-ring (D).

NOTE: Clean the strainer anytime the transmission is disassembled.