Reassembly
REASSEMBLYIntermediate Plate And Gear Assembly Top Gear Shaft. Main Shaft Gear And Counter Gear:
MINOR COMPONENTS
Important Operations
2. Needle Bearing
3. 2nd Gear
1. Apply engine oil to the needle bearing and the 2nd gear thrust surfaces.
2. Install the needle bearing and the 2nd gear to the mainshaft.
The dog teeth of the 2nd gear must be facing the rear side of the transmission.
5. 1st-2nd Synchronizer Assembly
1. Turn the clutch hub face (1) shallow toward the sleeve small groove (2) on the outer circumference.
2. Check that the inserts (3) fit snugly into the block ring insert grooves.
3. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5. Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the 2nd gear side.
6. Clutch Hub Snap Ring
1. Select the snap ring which will provide the minimum clearance between the 1st/2nd clutch hub and the snap ring.
There are three snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 (0.004) (mm (in))
Snap Ring Availability:
2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
Snap Ring Pliers
The snap ring must be fully inserted into the mainshaft snap ring groove.
7. Needle Bearing
9. 1st Gear
1. Apply engine oil to the needle bearing and the 1st gear thrust surfaces.
2. Install the needle bearing and the 1st gear to the mainshaft.
The 1st gear dog teeth must be facing the transmission front side.
10. 1st Gear Thrust Bearing
Install the thrust bearing to the mainshaft.
The thrust bearing side must be facing the transmission front side.
11. Mainshaft Ball Bearing
1. Apply engine oil to the ball bearing and the mainshaft.
2. Install the ball bearing to the mainshaft.
The ball bearing snap ring groove must be facing the transmission rear side.
3. Use a bench press to slowly force the ball bearing into place.
The ball bearing should meet the snap ring groove.
Installer : J-613301
13. Needle Bearing
14. 3rd Gear
1. Apply engine oil to the needle bearing and the 3rd gear thrust surfaces.
2. Install the needle bearing and the 3rd gear to the mainshaft.
The dog teeth of the 3rd gear must be facing the front side of the transmission.
16. 3rd-4th Synchronizer Assembly
1. Turn the clutch hub face (1) with the heavy boss (A) toward the sleeve small groove (2) on the outer circumference.
2. Check that the inserts (3) fit snugly into the block ring insert grooves.
3. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub and the sleeve slide smoothly.
5. Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the 3rd gear side.
17. Mainshaft Snap Ring
1. Select the snap ring which will provide the minimum clearance between the 3rd-4th clutch hub and the snap ring.
There are three snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 (0.004) (mm (in))
Snap Ring Availability:
2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
Snap Ring Pliers
3. The snap ring must be fully inserted into the mainshaft snap ring groove.
21. Ball Bearing
22. Top Gear Shaft Snap Ring
1. Use a bench press to install the top gear shaft ball bearing to the mainshaft.
The snap ring groove must be facing the transmission front side.
2. Use a pair of snap ring pliers to install the snap ring to the bearing.
Snap Ring Pliers
24. Front Ball Bearing
Use a bench press to install the counter gear front ball bearing to the mainshaft.
The snap ring groove must be facing the transmission front side.
Bearing installer : J-35283
26. Center Roller Bearing
1. Apply engine oil to the bearing inner and outer circumference.
2. Install the roller bearing in proper direction.
NOTE: Check that outer race moves only to arrow direction.
REVERSE GEAR AND 5TH GEAR
Important Operations
1. Intermediate Plate
1. Mesh the counter gear with the mainshaft assembly.
2. Install the holding fixture to the mainshaft and the counter gear.
Holding Fixture : J-37224
Holding base : J-3289-20
3. Place the holding fixture (with the mainshaft and the counter shaft) in a vise.
4. Install the intermediate plate.
3. Bearing Plate and Screw
1. Apply recommended thread locking agents or its equivalent to each of the plate screw threads.
2. Tighten the screws to the specified torque.
Torque bit (No. T45) : J-37225
Plate Screw Torque
1.5 (10.8/14.7) (kg-m (lb-ft/N-m))
Torx Bit Wrench : J-37225 (T45)
7. Rev.-5th Synchronizer Assembly
1. Turn the clutch hub face 1 toward the sleeve small groove 2 on the outer circumference.
2. Install the synchronizer assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be facing the reverse gear side.
8. Clutch Hub Nut
1. Mesh the 1st-2nd synchronizer with both the 1st and 3rd gears (double engagement).
This will prevent the mainshaft from turning.
2. Install the mainshaft lock nut.
3. Use the lock nut wrench to tighten the lock nut to the specified torque.
Hub Nut Torque
14 (101.3/137.2) (kg-m (lb-ft/N-m))
4. Use a punch to caulk the lock nut.
12. Counter Reverse Gear
1. Apply engine oil to the counter reverse gear and the reverse gear.
2. Install the counter reverse gear to the counter gear.
The reverse gear projection must be facing the side of the intermediate plate.
16. Reverse Idler Shaft
17. Counter 5th Gear
1. Set the counter 5th gear to the reverse idler shaft slot.
2. Install the reverse idler shaft together with the counter 5th gear to the transmission.
19. Bearing Snap Ring
1. Select the snap ring which will provide the minimum clearance between the ball bearing and the snap ring.
There are six snap ring sizes available.
The snap rings are color-coded to to indicate their thickness.
Ball Bearing and Snap Ring Clearance
Standard: 0 - 0.15 (0 - 0.0059) (mm (in))
Snap Ring Availability:
2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
Snap Ring Pliers
The snap ring must be fully inserted into the counter 5th gear snap ring groove.
20. Reverse Gear Snap Ring
1. Select the snap ring which will provide the minimum clearance between the intermediate plate and the snap ring.
There are three snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
Intermediate Plate and Snap Ring Clearance
Standard: 0 - 0.15 (0 - 0.0059) (mm (in))
Snap Ring Availability:
2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
Snap Ring Pliers
The snap ring must be fully inserted into the counter 5th gear snap ring groove.
21. Thrust Washer and Lock Ball
1. Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer.
5Th Gear and Thrust Washer Clearance
Standard: 0.10 - 0.25 (0.04 - 0.010) (mm (in))
If required, replace the existing thrust washer with a new thrust washer to bring the clearance to specification.
There are four thrust washer sizes available.
The snap rings are color-coded to indicate their thickness.
Thrust Washer Availability:
2. Apply grease to the thrust washer and the lock ball.
3. Install the thrust washer and the lock ball to the mainshaft.
24. Roller Bearing
Use the installer to install the roller bearing to the mainshaft.
Installer : J-37223
DETENT, SHIFT FORK ASSEMBLY AND INTERLOCK PIN
Important Operations
2. 1st-2nd Shift Arm
3. 3rd-4th Shift Arm
Hold a round bar (1) against the shift rod end lower face (2) to protect it against damage.
Install the new spring pin.
Never reinstall the used spring pin.
4. 3rd-4th Shift Rod
5. Interlock pin
1. Install the interlock pin to the shift rod.
2. Install the shift rod together with the interlock pin to the intermediate plate.
Do not allow the interlock pin to fall from the shift rod.
12. Detent Spring Plate
Tighten the detent spring plate bolts to the specified torque.
Detent Spring Plate Bolt Torque
1.5 (10.8/14.7) (kg-m (lb-ft/N-m))
TRANSFER CASE ASSEMBLY AND MAINSHAFT GEAR
Important Operations
1. Transfer Case
1. Cover the shaft spline with adhesive tape (1).
This will prevent damage to the oil seal lip (2).
2. Apply recommend liquid gasket or its equivalent to the transfer case fitting surfaces.
3. Tighten the transfer case bolts to the specified torque a little at a time.
Transfer Case Bolt Torque
3.8 ± 0.8 (27.5 ± 5.8/39.24 ± 7.84 (kg-m (lb-ft/N-m))
2. Transfer Counter Gear
3. Sub Gear
Apply chassis grease to the sub-gear and the counter gear thrust surfaces.
Bearing And Snap Ring Clearance:
7. Bearing Inner Snap Ring
1. Select a snap ring that will allow the minimum axial play.
2. Use a pair of snap ring pliers to install the snap ring to the counter gear.
14. Front Output Gear
16. Sub Gear
17. Belleville Spring
18. Spacer
Apply engine oil to the thrust surfaces of the sub-gear, the belleville spring, and the spacer.
19. Sub Gear Snap Ring
20. Bearing Collar
Use a bench press to install the needle bearing and collar together with the front output gear.
Bearing And Snap Ring Clearance:
22. Bearing Snap Ring
1. Select a snap ring that will allow the minimum axial play.
2. Use a pair of snap ring pliers to install the snap ring to the output shaft.
Sub Gear Preload
1. Hook a length of piano wire over one of the sub-gear teeth.
2. Attach the other end of the piano wire to a spring balancer.
3. Measure the sub-gear preload.
Sub-Gear Preload
Standard: 5 - 12 (11.0 - 26.5/49.0 - 117.6) (kg (lb/N))
29. Mainshaft End Lock Nut and Washer
1. Use the lock nut wrench to tighten the mainshaft end lock nut to the specified torque.
Lock Nut Wrench : J-37219
Mainshaft End Lock Nut Torque
13 ± 1 (94.0 ± 7.2/129.4 ± 9.8) (kg-m (lb-ft/N-m))
2. Stake the lock nut.
37. Interlock Pin
1. Engage the High-Low synchronizer with the rear output gear.
2. Install the interlock pin.
Be absolutely sure that the interlock pin is installed in the proper direction.
45. Plug
Tighten the plugs to the specified torque.
Plug Torque
1.9 ± 0.4 (13.7 ± 2.9/18.6 ± 3.9) (kg-m (lb-ft/N-m))
46. Switch
Tighten the switch to the specified torque.
Switch Torque
4 (29.0/39.2) (kg-m (lb-ft/N-m))
TRANSFER REAR CASE ASSEMBLY
Important Operations
2. Ball Bearing
Use the bail bearing installer and the adapter to install the ball bearing.
Ball Bearing Installer : J-37223
Adapter : J-37486
4. Clip
Install the clip to the drive gear groove.
7. Ball Bearing
Use the ball bearing installer to install the ball bearing.
Ball Bearing Installer : J-37223
MAJOR COMPONENTS
Important Operations
2. Transfer Rear Case Assembly
1. Apply recommended liquid gasket or its equivalent to the transfer rear case fitting faces.
2. Install the rear transfer case assembly to the transfer case assembly.
3. Tighten the rear transfer case bolts to the specified torque.
Transfer Case Bolt Torque
3.8 ± 0.8 (27.5 ± 7.8/37.2 ± 7.8) (kg-m (lb-ft/N-m))
3. Counter Gear Snap Ring
4. Bearing Snap Ring
Use a pair of snap ring pliers to install the snap ring to the mainshaft.
Snap Ring Pliers
The snap ring must be fully inserted into the ball bearing snap ring groove.
5. Front Cover with Oil Seal
1. Apply recommended liquid gasket or its equivalent to the through bolt threads.
The through bolts are located at the lower side of the transmission case (viewed from the front of the transmission).
2. Install the front cover with oil seal to the transmission case.
Take care not to damage the oil seal.
3. Tighten the front cover bolts to the specified torque.
Front Cover Bolt Torque
1.9 (13.7/18.6) (kg-m (lb-ft/N-m))
6. Transfer Flange
1. Use the flange holder to install the flange to the rear transfer case.
Flange Holder : J-27221
2. Tighten the transfer flange bolts to the specified torque.
Transfer Flange Bolt Torque
14 (101.3/137.2) (kg-m (lb-ft/N-m))