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), magnet set plate (B), differential assembly (C), and reverse lock cam (D).





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. Tape the mainshaft splines (D) with vinyl tape 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 idler gear (A) and reverse gear shaft (B).





5. Install the reverse shift fork (A) and MBS cam holder (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 seal 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. Install the 14 x 20 mm dowel pins (A).
9. 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.
10. Check that the 52 mm snap ring is securely seated in the groove of the countershaft bearing.
Dimension (2) as installed: 4.6 - 8.3 mm (0.18 - 0.33 inch)
11. Apply liquid gasket (P/N 08718-0001) to the threads of the 32 mm sealing cap (C), and install it on the transmission housing.





12. Install the transmission hanger (A) and the 8 mm flange bolts finger-tight.





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





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





15. Install the 8 x 10 mm dowel pins (A) and shift arm cover (B).





16. Apply liquid gasket (P/N 08718-0001) to the threads of the set screws, then install the set screws (A), springs, and steel balls.
17. Apply liquid gasket (P/N 08718-0001) to the threads of the back-up light switch (B) and neutral position switch (C). Install the switches.





18. Install the drain plug (A), filler plug (B), O-ring (C), and vehicle speed sensor (VSS) (D).