Step 4

NOTE:
a. Wash all parts.
b. Apply oil to all friction surfaces.
c. Use new roll pins and retaining rings.




Torque Specifications




1. Install the magnet and the differential assembly.
2. Install the primary shaft gear assembly and the secondary shaft gear assembly together.




3. Shift to 2nd gear and position the shift fork and shift rod assembly as shown.




4. Insert the spring seat and spring into the reverse lever shaft, install the steel ball, and place a scraper knife so that it contacts the steel ball.
5. With the edge of the control end against the knife, when the control end is pushed in the direction of the arrow in the image so that the ball goes into the shaft, the rod will at the same time line up with the shift rod coupling hole in the clutch housing.




6. Set each clutch hub sleeve to the neutral position, and tap the shift rod from above so that the steel ball goes into the center groove (of the 3 grooves in the control end).
7. Pull the ball part of the control end forward so that the steel ball goes into the detent in the groove.




8. Fit the crank lever in between the change arm and the control end, and connect the crank lever shaft to the crank lever.
9. Align the pin holes of the crank lever shaft and the clutch housing, and insert the pin.

NOTE: Use a new O-ring for the crank lever shaft.




10. Install the gate (1) and the shift rod (2), and tighten the gate mounting bolt.

NOTE: The mark (indicated by the arrow in the image) and the gate mounting bolt hole must be in the same direction.




11. Install the reverse idle gear and the reverse idle shaft.
12. Connect the magnet to the clutch housing.
13. Align the end of the interlock sleeve with the control lever indicated by the arrow, and, at the same time, face the reverse idle shaft screw hole in the direction shown in the image.




14. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transmission case, tighten the transaxle case installation bolts to the specified torque.

Tightening torque: 18-26 N.m (1.8-2.7 m-kg, 13-18.8 ft-lb)

15. Insert the SST to driveshaft coupling hole.




16. Install the lock bolt (1), the guide bolt (2).
17. Install the ball, spring and lock bolt (3).

Tightening torque:
1. 18-26 N.m (184-264 cm-kg, 159-228 in-lb)
2. 9-14 N.m (90-140 cm-kg, 78-121 in-lb)
3. 15-21 N.m (150-210 cm-kg, 129-181 in-lb)

NOTE: Check that gear change operation is smooth.




18. Install the secondary 5th gear as shown.




19. Install the gear sleeve, the 5th gear and synchronizer ring to primary shaft.




20. Tap in the roll pin.
21. Install the synchronizer ring and the reverse synchronizer gears.




22. Shift to 1st gear.
23. Lock the primary shaft with the SST.
24. Tighten new lock nuts.

Tightening torque: 128-196 N.m (13.0-20.0 m-kg, 94-145 ft-lb)

25. Stake the lock nuts.




26. Clean and coat the both surface and install the rear cover.

Tightening torque: 8-11 N.m (80-110 cm-kg, 68-95 in-lb)