Reassembly

REASSEMBLY





1. Measure the depth (A) between the bottom of the main shaft double bearing seat in the adapter and the sealing surface of the adapter.





2. Measure the thickness (B) of main shaft double bearing.
Measured value: A-B
End play: 0 - 0.1 mm (0 - 0.0039 inch)
Select a shim that is equal to the measured value considering the end play.





3. Measure the depth (A) between the bottom of the counter shaft bearing race seat in the transmission case housing and the sealing surface of case housing.





4. Install the counter shaft and temporarily taper bearing outer race. Measure the height (B) between the sealing surface of adapter and the upper face of the bearing race (located on the counter shaft).
Measured value: A - B
End play: 0.02 - 0.12 mm (0.0008 - 0.0047 inch)
Select a shim that is equal to the measured value considering the end play.





5. Install the outer race and selected shim into the counter shaft taper bearing seat of adapter.





6. Install the selected shim into the main shaft bearing seat.





7. Install two dowel pins into the grooves of the sealing surface of the adapter.





8. Insert two interlock balls into the grooves in the rail holes.





9. In order to secure two interlock balls, temporarily install flexible hoses into the rail holes.





10. Match up and secure the main shaft, counter shaft and 1st & 2nd and 5th R shift fork assembly with a strap or cord for ease of installation. Then, hang them on the jack or suitable crane. Because it is dangerous to pick up them with hands.

NOTE: Do not install 3rd & 4th shift fork and rail.





11. Heat the main shaft double bearing seat part in adapter with electrical heater (Leister 4000) or SST (09432-3E000).





12. Install the main shaft, counter shaft and shift fork assembly into the adapter after removing two flexible hoses installed temporarily.





13. Insert 3rd & 4th shift rail into the rail hole.

NOTE: Make sure to set each gear to the neutral position before inserting. Be careful not to fall out interlock ball into the adapter when inserting 3rd & 4th shift rail.





14. Using the pin punch, install 3rd & 4th shift fork pin.





15. Tighten reverse idle shaft bolt and washer on the adapter side.
Tightening torque: 43 - 55 Nm (430 - 550 kg-cm, 31 - 40 ft. lbs.)





16. Tighten three rear bearing retainer bolts with washer.
Tightening torque: 20 - 27 Nm (200 - 270 kg-cm, 14-15 ft. lbs.)





17. Using SST (09432-3E700), install oil seal on the adapter housing.

NOTE: Apply the grease to the oil seal.





18. Install steel balls, poppet springs and interlock poppet plate.
Tightening torque: 10 - 12 Nm (100 - 120 kg-cm, 7 - 9 ft. lbs.)





19. Install control lugs in the end of shift control rails.





20. Insert new roll pins into the control lugs and shift rails.





21. Insert two dowel pins into the grooves on the sealing surface of shift control housing in adapter.





22. Measure the depth (A) of front retainer bearing seat in the outside of the transmission case housing (clutch housing side).





23. Measure the height (B) from contacting surface of front case retainer.





24. Measure height (C) of retainer bearing from contacting surface of snap ring.
Measured value: A-B-C
End play: 0 - 0.1 mm (0 - 0.0039 inch)
Select a shim that is equal to the measured value considering the end play.
25. Install outer race and spacer on the counter shaft taper bearing.





26. Install the transmission case housing onto the sealing surface of the adapter.
Tightening torque: 43 - 55 Nm (430 - 550 kg-cm, 31 - 40 ft. lbs.)

NOTE: Apply sealant to the sealing surface of adapter housing.





27. Install reverse idle shaft bolt on the case housing side.
Tightening torque: 43 - 55 Nm (430 - 550 kg-cm, 31 - 40 ft. lbs.)





28. Using SST (09432-3E900), install the front retainer oil seal.

NOTE: Apply grease to the oil seal.





29. Install front bearing in the case housing.





30. Install the selected spacer on the front retainer.

NOTE: Apply grease to spacer.





31. Tighten the front retainer bolts.
Tightening torque:
Flange bolt: 20 - 27 Nm (200 - 270 kg-cm, 14 - 20 ft. lbs.)
Fulcrum bolt: 30 - 42 Nm (300 - 420 kg-cm, 22-30 ft. lbs.)

NOTE: Apply grease to the contacting surface of the case housing.





32. Tighten oil drain plug and new washer.
Tightening torque: 60 - 65 Nm (600 - 650 kg-cm, 43 - 48 ft. lbs.)





33. Install back lamp switch and washer.
Tightening torque: 30 - 35 Nm (300 - 350 kg-cm, 22 - 25 ft. lbs.)





34. Install shift control case on the adapter housing.
Tightening torque: 20 - 27 Nm (200 - 270 kg-cm, 14 - 20 ft. lbs.)

NOTE: Apply sealant to the sealing surface of the adapter housing.





35. Install shift control lever assembly.
Tightening torque: 20 - 27 Nm (200 - 270 kg-cm, 14 - 20 ft. lbs.)

NOTE: Apply sealant to the sealing surface of shift control case.





36. Install release fork tube, release bearing and release fork.

NOTE: Apply grease to spread bearing sliding surface and holes of release fork. Apply grease to bearing inner face and groove.