Shift Control Housing

Shift Control Housing





Transmission Shift Components - Disassembled View









Disassembly

1. NOTE: Do not disassemble the shift bar housing to determine if parts have worn. Visually inspect the condition of the shift fork rails and forks. If the forks have excessive wear or if they bind when shifted into the various positions, disassemble the shift bar housing to carry out repairs.

Inspect the shift control assembly.

2. Remove the lower gearshift lever.

1. Remove the 3 dust cover screws.

2. Remove the dust cover.

3. Remove the lower gearshift lever.





3. Remove the reverse lamp switch and the actuating pin.





4. Invert the case cover on the Transmission Holding Fixture.





5. NOTE: Place the shift mechanism in the neutral position.

Remove and discard the shift fork spring pins.





6. Remove and discard the shift gate spring pins.





7. Remove the 3 rubber service bore plugs.









8. NOTICE: Carry out the following shift rail removal procedure carefully. Cover the detent ball bores and spring seats with a clean cloth held firmly into place during shift rail removal. Failure to cover the bores may result in component loss when the detent ball and spring forcefully leave their installed positions.

NOTE: When removing the shift rails, collect and separate the interlock pins to make sure of installation into their original locations.

Remove the 5th/reverse shift rail.

- Use a suitable punch in the spring pin bore to aid removal.





9. Remove the 1st/2nd shift rail.
- Use a suitable punch in the spring pin bore to aid removal.





10. Remove the 3rd/4th shift rail.
- Use a suitable punch in the spring pin bore to aid removal.





11. Remove the gear selector interlock sleeve.

1. Remove the 3 bolts.

2. Remove the gear selector interlock sleeve.





Assembly

1. Insert a shift fork into a synchronizer sleeve. Inspect the contact surface between the shift fork and the synchronizer sleeve for wear.





2. Install the gear selector interlock sleeve.

1. Position the gear selector interlock sleeve.

2. Install the 3 bolts.





3. NOTE: Incorrect installation of the interlock pins will prevent activation of the backup lamp switch.

Install the interlock pins into their original shift rails.





4. Position the detent ball and spring, the shift gate, the shift fork and spring, then install the 1st/2nd shift rail.





5. Position the detent ball and springs, the shift gate, the shift fork and spring, then install the 3rd/4th shift rail.





6. Position the 5th/reverse shift control, the detent ball and spring and the shift gate, then install the 5th/reverse shift rail.





7. Install the 3 rubber service bore plugs.





8. NOTE: Leave 1.5 mm (0.059 in) of the pin showing above the shift gate.

Install new shift gate spring pins.





9. NOTE: Leave 1.5 mm (0.059 in) of the pin showing above the shift fork.

Install new shift fork spring pins.





10. Install the reverse lamp switch.

1. Install the reverse lamp switch pin.

2. Install the reverse lamp switch.
- Tighten to 30 Nm (22 lb-ft).





11. Install the lower gearshift lever.

1. Position the gearshift lever.
- The notch on the gearshift lever must be installed facing the front of the transmission.

2. Position the dust cover.

3. Install the 3 bolts.
- Tighten to 9 Nm (80 lb-in).