20. Transmission Reassembly

Transmission Reassembly

NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces,





1. Install the magnet (A), differential assembly (B), and reverse lock cam (C).





2. Install the 36 mm spring washer (A) and 26 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer (A).
3. Apply vinyl tape the mainshaft splines (D) to protect the seal. Install the mainshaft and countershaft (E) into the shift forks (F), and install them as an assembly.





4. Install the reverse shift fork.





5. Install the reverse idler gear (A) and reverse gear shaft (B).





6. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).





7. Remove the dirt and oil from the transmission housing sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface. Be sure to sea[ the entire circumference of the bolt holes to prevent oil leakage.

NOTE: If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.





8. Set the tapered cone ring (A) as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.





9. Install the 14 x 20 mm dowel pins (A).
10. Lower the transmission housing the rest of the way as you expand the 52 mm snap ring (B). Release the snap ring so it seats in the groove of the countershaft bearing.
11. Check that the 52 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (D as installed: 4.6 - 8.3 mm (0.18 - 0.33 inch)
12. Apply liquid gasket (P/N 08718-0001) to the threads of the 32 mm sealing cap (C), and install it on the transmission housing.





13. Install the 8 mm flange bolts finger-tight.





14. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.





15. Remove the dirt and oil from the shift [ever cover sealing surface. Apply liquid gasket (P/N 08718-0001) to the sealing surface.








16. Install the 8 x 10 mm dowel pins (A) and shift lever assembly (B).





17. Install the select lever assembly.





18. Install the detent bolts (A), back-up light switch (B) with a new washers, then install the transmission hanger (C).





19. Install the drain plug (A) and the filler plug (B) with new washers.
20. Install the 0-ring (C) and the vehicle speed sensor (VSS) (D).