Part 2 of 2

REASSEMBLY
21. Install the reverse-5th shift rod.
a. Install the reverse shift arm No. 1 lock ball to the reverse shift arm No. 1.

b. Install the interlock pin to the intermediate plate.

c. Put in the reverse-5th shift rod from the front.

d. Using a screwdriver and a hammer, install the 2 new shift rod snap rings to the 5th-reverse shift rod and reverse shift rod.
22. Install 1st-2nd shift rod.

a. Install the interlock pin to the intermediate plate.

b. Put in the 1st-2nd shift rod from the rear.
23. Install 3rd-4th shift rod.

a. Install the straight pin interlock pin to the intermediate plate.

b. Put in the 3rd-4th shift rod from the rear.
24. Install the interlock parts.

a. Using a screwdriver and hammer, 2 new shift rod snap rings to the 1st-2nd and 3rd-4th shift rod.

b. Install the 3 shift detent ball and springs to the intermediate plate.
c. Clean up the plug hole.
d. Apply sealant to the plug threads.
sealant: three bond 1344 or equivalent

e. Using a torx socket wrench (T40) install and torque the 4 plugs.
Torque: 18.5 Nm (13.5 ft. lbs.)
25. Install main shaft assembly.

NOTE: Coat all parts with gear oil before installing them.

a. Using a plastic hammer, tap the 5th-reverse shift rod at the reverse shift.

b. Install the shift arm No. 1 and No. 2 to the mainshaft.

c. Using a plastic hammer, tap the intermediate plate and install the mainshaft through the shift arm No. 1 and No. 2 to the shift rod.

d. Using a snap ring expander, install the snap ring.

e. Using a plastic hammer, tap the 5th-reverse shift rod at the neutral shift.

26. Install the top gear shaft.
a. Align the projection of the hub No.2 with the synchronizer ring slots, and install the top gear shaft assembly to the mainshaft.
b. Check that the top gear shaft rotates smoothly.
27. Install the counter gear shaft.

a. Temporarily install the counter gear shaft to the intermediate plate.

b. Using installer J-42796 and a hammer drive in the center bearing as shown.

NOTE: Outer race snap ring groove toward rear.

Reference: Drive in the counter rear bearing by tapping on the front end of the counter shaft.

28. Install the reverse idle gear.
a. Install the reverse idle gear and reverse idle gear shaft.

NOTE:
- Insert the reverse idle gear shaft with the slot toward rear.
- Install the reverse idle gear with the reverse shift arm No. 2.

29. Install the bearing plate.
a. Align the bearing plate to groove of the reverse idle gear shaft.
Torque: 12.5 Nm (109 inch lbs.)

30. Install the 5th gear thrust washer.
a. Install the 5th gear thrust washer pin to the counter gear shaft.
b. Install the 5th gear thrust washer to the counter gear shaft.
31. Install the counter 5th gear.

a. Install the 3 inserts and reverse block ring. Install 3 compression springs to the reverse block ring.

Reference: Push the 3 inserts with the 3 compression springs to the reverse synchronizer ring.

b. Install the synchronizer outer ring, synchronizer cone ring, and synchronizer pull ring to the reverse block ring.

c. Turn to 30 degree the reverse synchronizer pull ring.

d. Install the hub sleeve No.3 and reverse block ring set to the counter 5th gear.

NOTE: Check the hub sleeve No.3 direction, as shown.

Reference: While pushing the 3 inserts, install the synchronizer ring assembly to the hub sleeve No.3.

e. Slide the hub sleeve No.3.

f. Install the counter 5th gear bearing, counter 5th gear and reverse block ring set to the counter gear shaft, through the 5th reverse shift arm to the 5th reverse shift rod.

g. Using installer J-42796 and a press, install counter 5th gear spline piece.

NOTE:
- Align the projection of the cone ring to the holes of the 5th gear spline piece.
- Check that the gear rotates smoothly.

h. Using thickness gauge, measure the counter 5th gear thrust clearance.
Standard: 0.10 - 0.35 mm (0.004 - 0.014 inch)

i. Select a snap ring that will allow minimum axial play.

j. Install the new snap ring.

32. Install the shift arm bolts.
a. Install and torque the 2 shift arm bolts.
Torque: 19.5 Nm (14 ft. lbs.)

33. Install the shift arm slotted pin.
a. Using a pin punch and a hammer, drive in the slotted pin to the shift arm.
34. Install the transmission case.
a. Clean up the fitting surface.

b. Apply recommended liquid gasket (THREE BOND 1281 or equivalent), as shown.

NOTE:
- Don't dry the liquid gasket.
- Apply the liquid gasket (THREE BOND 1281 or equivalent) line, as shown.

c. Stand the transmission by the wood blocks.

d. Using a plastic hammer, tap the transmission case and attach it to the intermediate plate.

NOTE: Be careful not to add over force to bearing.

e. Using a snap ring expander, install the front bearing shaft snap ring (1) and counter gear shaft bearing snap ring (2).
f. Turn over the transmission.
35. Install the front cover.
a. Clean up the fitting surface.

e. Using 8 bolts, install the front cover to the transmission case.
Torque: 16.5 Nm (12 ft. lbs.)

NOTE:
- Tighten the all bolts evenly.
- Be careful not to damage the oil seal.

f. Check that the top gear shaft and mainshaft rotate.
36. Install the transfer adapter.
a. Clean up the fitting surface.

b. Apply recommended liquid gasket (THREE BOND 1281 or equivalent), as shown.

NOTE: Don't dry the liquid gasket.

c. Using a plastic hammer, tap the transfer adapter and attach it to the intermediate plate.

d. Using 10 bolts, install the transfer adapter.
Torque: 37 Nm (27 ft. lbs.)

NOTE:
- Tighten the all bolts evenly.
- Don't damage the lip of the oil seal.
- Install the wire clamp (9) to the transfer adapter.

37. Install the gear control box.

a. Align the projection of the shift lever housing to the shaft shift rod groove, and install the shift lever shaft.

b. Using a pin punch and hammer, drive in the slotted spring pin (2) to the shift lever housing.

NOTE: Be careful not to drop the slotted spring pin.

c. Apply sealant (THREE BOND 1344 or equivalent) to the plug (1) thread.

d. Using hexagon wrench, install and torque the plug (1).
Torque: 18 Nm (13 ft. lbs.)
e. Clean up the bolts and bolt hole.

f. Using 6 bolts, install the gear control box through the gasket.
Torque: 18 Nm (13 ft. lbs.)

38. Install clutch housing.
a. Install the clutch housing to the transmission case.
Torque: 36 Nm (27 ft. lbs.)

NOTE: Tighten the all bolts evenly.

39. Install the switches.
a. Install the new gasket to the 1st and 2nd switch.
b. Install the 1st and 2nd switch assembly (8).
Torque: 39 Nm (29 ft. lbs.)
c. Install the new gasket to the 3rd and 4th switch.
d. Install the 3rd and 4th switch assembly (7).
Torque: 39 Nm (29 ft. lbs.)
e. Install the new gasket to the backup light switch.
f. Install the backup light switch assembly (6).
Torque: 44 Nm (33 ft. lbs.)

40. Install the clutch release bearing (3) and release shift fork (5).
a. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
b. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
c. Install the clutch shift fork (5).
d. Install the snap pin.
e. Install the clutch release bearing (3) to the clutch shift fork (5).

41. Install the drain plug and case plug.
a. Install the drain plug (1) through the new gasket.
Torque: 37 Nm (27 ft. lbs.)
b. Install the filler plug (2) through the new gasket.
Reference: Plug after the gear oil fill in.
Torque: 37 Nm (27 ft. lbs.)