9. Transmission Assemble

Transmission Assemble

Special Tools
* J 3289-20 (KM 113-2) - Holding Fixture
* J 36633 - Snap Ring Retainer
* KM-334 - Installer Sleeve
* KM-552 - Fixture
* KM-554 - Installer

Assembly Procedure




1. Join the mainshaft and the input shaft.
2. Compress the snap ring at the base of the mainshaft and hold with J 36633 (1).
3. Hold the snap ring at the base of the input drive shaft with the snap ring pliers.
4. Install the mainshaft/input shaft assembly onto the bearing plate.
5. Release the mainshaft snap ring and the input shaft snap ring.




6. Position the 1st-2nd gearshift fork.
7. Install the 5th gearshift lever into the bearing plate.




8. Install the 3rd-4th gearshift rod/fork holding pin.




9. Install the support bracket onto the bearing plate.




10. Install the 1st-2nd gearshift rod/fork onto the bearing plate.




11. Install the 1st-2nd gearshift fork holding pin.





Caution: Refer to Fastener Caution (Fastener Caution).

12. Install the support bracket bolts and tighten to 7 Nm (62 lb in).




13. Install the reverse gearshift rod/fork on the bearing plate.




14. Install the reverse gearshift rod/fork holding pin.




15. Install the rod lock pin and spring into the small plug hole.




16. Install the 4th gearshift rod plugs.




17. Install the 5th gearshift connector onto the bearing plate, using the pawl.
18. Install the 5th gearshift connector bolts and tighten to 7 Nm (62 lb in).




19. Install the input drive 5th gear using KM-554 (2) and KM-334 (1).




20. Install the snap rings securing the 5th drive gear.




21. Install the thrust washers, the retaining ring, and the needle bearing into the mainshaft-driven 5th gear assembly.




22. Install the brass synchronizer ring onto the mainshaft-driven 5th gear assembly.




23. Install the mainshaft-driven 5th gear assembly.
24. Install the 5th drive gear synchronizer gear and the synchronizer sleeve using KM-554 (1).




25. Install the snap ring holding the 5th speed-driven assembly.




26. Install the 5th gear fork onto the bearing plate.
27. Install the 5th gear fork bolts and tighten to 22 Nm (16 lb ft).




28. Remove the bearing plate from the fixture.
29. Shift the transaxle into the 2nd gear.
30. Install the bearing plate, with the shafts attached, into the case.




31. Install the bearing plate bolts and tighten to 22 Nm (16 lb ft).




32. Install the speedometer-driven gear into the transaxle housing.
33. Install the speedometer-driven gear bolt and tighten to 4 Nm (35 lb in).




34. Bolt the gearshift lever cover to KM-552 (2).
35. Position the fixture into the base J 3289-20 (3).
36. Install the gearshift rod (1), the shift finger lever, and the gearshift lever pin.




37. Install the snap ring, the bushing, the spring, and the intermediate lever.
38. Remove the gearshift lever cover from the base and the fixture.
39. Shift the transaxle into NEUTRAL.




40. Install the gearshift lever cover.
41. Install the gearshift lever cover bolts and tighten to 22 Nm (16 lb ft).




42. Install the transaxle cover.
43. Install the transaxle cover bolts and tighten to 18 Nm (13 lb ft).
44. Install the transaxle into the vehicle. Refer to Transmission Replacement (D16 - Manual Transmission).