Reassembly

Top Gear Shaft, Main Gear Shaft, 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 2nd gear dog teeth must be facing the transmission rear side.

7. 1st-2nd Synchronizer Assembly
1. Turn the clutch hub dished face (1) 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.

Snap Ring Availability:

8. 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 Snap Ring Clearance Standard: 0 - 0.1 (0 - 0.0039) mm (in)

2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the main- shaft snap ring groove.

9. Needle Bearing

13. 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.

14. 1st Gear Thrust Bearing
Install the thrust bearing and the race to the main shaft.
The thrust bearing side must be facing the transmission front side.

15. Mainshaft Ball Bearing
16. Needle Bearing Collar
1. Apply engine oil to the ball bearing and the main- shaft.
2. Install the ball bearing and collar 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 collar into place.
Installer J-6133-O1

17. Needle Bearing
18. 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 3rd gear dog teeth must be facing the transmission front side.

20. 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 (5) and the sleeve (6) slide smoothly.
5. Install the synchronizer assembly to the main shaft. The clutch hub face (with the heavy boss) must be facing the 3rd gear side.

Snap Ring Availability:

21. 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 - 0.0039) mm (in)

2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the main- shaft snap ring groove.

25. Ball Bearing
26. 4th Gear Shaft Snap Ring
1. Use a bench press to install the 4th 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.

28. Front Roller Bearing
1. Apply engine oil to the bearing and install the inner race (1) and outer race with roller (2) in the proper direction to the mainshaft.
2. Then install the inner race (3) with taper side turned to outer race (2).

NOTE: The inner race (3) should be installed with stamp on die face side turned to the front side of transmission.
See the illustration.

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 countershaft) 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 bearing plate screw threads.
2. Tighten the screws to the specified torque.
Torx Bit Wrench: J-37225 (T45)

Bearing Plate Screw Torque: 1.5 (10.8/14.7) kg-m (lb-ft/N-m)

7. Rev-5th Synchronizer Assembly
1. Turn the clutch hub face (1) 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 reverse gear side.

8. Mainshaft 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 hub nut.
3. Use the mainshaft nut wrench to tighten the mainshaft nut to the specified torque.
Wrench: J-37219

Mainshaft Nut Torque: 14 ± 2 (101.0 ± 14.2/137.2 ± 19.6) kg-m (lb-ft/N-m)

4. Use a punch to caulk the mainshaft 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. Note the projection at either side of the counter reverse gear.
The larger projection must be facing the intermediate plate.

15. 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 indicate their thickness.

Ball Bearing and Snap Ring Clearance standard: 0 - 0.15 (0 - 0.0059) mm (in)

2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the counter 5th gear snap ring groove.

21. 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 - 0.14 (0 - 0.0055) mm (in)

Snap Ring Availability:

2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the counter 5th gear snap ring groove.

22. Thrust Washer and Lock Ball
1. Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer.

Standard: 0.10 - 0.25 (0.004 - 0.0010)

If required, replace the existing thrust washer with a new thrust washer to bring the clearance to specification.

Thrust Washer Availability:

There are four thrust washer sizes available.
The thrust washers are color-coded to indicate their thickness.
2. Apply grease to the thrust washer and the lock ball.
3. Install the thrust washer and the lock ball.

29. Ball Bearing
Use the installer to install the ball bearing to the mainshaft.
Installer: J-37223

INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT ARM ASSEMBLY, AND INTERLOCK PIN

Important Operations

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: 2.0 ± 0.4 (14.4 ± 2.9/19.6 ± 3.4) kg .m (lb-ft/N-m)

MAJOR COMPONENTS

Important Operations
1. Intermediate Plate with Gear Assembly
1. Apply a light coat of oil to the transmission case top gear shaft ball bearing fitting faces and the shift rods. This will facilitate smooth installation.
2. Install the intermediate plate assembly.
3. Pull out the top gear shaft until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or stress.

2. Rear Cover with Oil Seal
3. Transmission Case
1. Apply recommended liquid gasket or its equivalent to the transmission case and rear cover fitting surfaces.

2. Install the rear cover and the transmission case to the intermediate plate.
3. Tighten the rear cover bolts to the specified torque.

Rear Cover Bolt Torque: 4.0 ± 0.2 (28.9 ± 1.4/39.2 ± 1.96) kg-m (lb-ft/N-m)

4. Front Bearing Snap Ring
5. Counter Front Bearing Snap Ring
Use a pair of snap ring pliers to install the snap rings to the mainshaft.
The snap rings must be fully inserted into the ball bearing snap ring groove.

6. Front Cover with Oil Seal
1. Apply recommended liquid gasket or its equivalent to the through bolt threads.
2. Install the front cover 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)