Transmission Assemble

Transmission Assemble

Special Tools

* 3-9506289 - Universal Adapter

* R-0007758 - Holding Fixture

* S-9407197 - Differential Rotating Tool

* S-9407198 - Differential Bearing Race Wrench

For equivalent regional tools, refer to Special Tools F13-5/F15-5/F17-5 (M26) - Manual Transmission.





1. Install the clutch and differential housing assembly (1) onto the R-0007758 - holding fixture.





2. Install the front differential carrier (1).





3. Install the gasket (3) and differential carrier cover (2).

4. Install the front differential carrier cover bolts (1). Tighten to 7 Nm (61.96 lb in).





5. Lubricate the O-ring seal (2) with multipurpose grease and install onto the differential bearing adjuster (1).

6. Lubricate the threads on the differential bearing adjuster with multipurpose grease.

7. Using S-9407198 - differential bearing race wrench install the front differential bearing adjuster (1).





Note:
If all the components are re-used align adjuster to marks. If any component was replaced go to the next step.

8. Align marks on the differential bearing adjuster and case (1).





Note:
If no components were replaced, the bearing adjuster can be aligned to the marks. If any component was replaced, the following procedure must be performed.

9. Using the S-9407197 - differential rotating tool and a torque wrench, rotate the differential (1) 1 revolution per second.

10. The breakaway bearing torque should be:

* Re-use bearing - 60-100 Ncm

* New Bearing - 150-210 Ncm

11. Using the S-9407198 - bearing race wrench and the R-0007761 - handle, adjust the breakaway torque by tightening or loosing the differential bearing adjuster.





12. Install the differential bearing adjuster lock (2).

13. Apply thread locking compound and install the differential bearing adjuster lock bolt (1). Tighten to 9 Nm (79.66 lb in).





14. Install the back up lamp switch (1). Tighten to 20 Nm (14.75 lb ft).





15. Install the reverse idler gear washer (5).

16. Verify fork alignment before installation.

17. Install the case.

18. Install the gasket (1) and transmission case (2).

19. Install the transmission case bolts (3). Tighten to 15 Nm (11 lb ft).





20. Install the gasket (1) and transmission cover (2).

21. Install the transmission cover bolts (3). Tighten to 15 Nm (11 lb ft).





22. Install the clutch release bearing (1).





23. Install the gasket (3) and control lever housing (2).

24. Install the transmission control lever housing bolts (1). Tighten to 12 Nm (106 lb in).





25. Install the clutch fork shaft (1).

26. Install the clutch fork shaft retaining bolt (2). Tighten to 35 Nm (26 lb ft).





27. Remove the R-0007758 - holding fixture (2) and the 3-9506289 - Universal Adapter (1).