Assembly

Clutch Hub
1. Place the 3rd gear and synchronizer ring on the mainshaft.
2. Press the clutch hub assembly (3rd/4th) on using a suitable pipe and pulley boss puller (49 0636 145).






CAUTION: Align the synchronizer ring and clutch hub when installing




3. Insert the snap ring using snap ring pliers.




4. After mounting the 2nd gear and synchronizer ring on the mainshaft, use a suitable piece of pipe to press the clutch hub assembly (1st/2nd) on.

CAUTION: Align the synchronizer ring and clutch hub when installing.






NOTE: Press each clutch hub assembly on to the mainshaft in the proper direction.




5. Assemble the gear sleeve, 1st gear and washer to the mainshaft, install the needle bearing, synchronizer ring and main drive gear.




Bearing Housing
1. Use a suitable piece of pipe to press the bearing into the bearing housing.




2. Measure the clearance between the bearing and the bearing housing.
If the clearance is not as specified, adjust it by using an adjust shim(s).

Standard clearance: 0 ± 0.05 mm (0 0.002 in)
Adjust shim: 0.1 mm (0.004 in), 0.3 mm (0.012 in)




3. Install the bearing cover to the bearing housing.

Tightening torque:
Bearing cover 18 - 26 N-m (1.8 - 2.7 m-kg, 13 - 20 ft-lb)




4. Install the mainshaft and main drive gear assembly and the countershaft gear.
Use a suitable round bar to press in the countershaft.




Reverse Idle Gear
1. Mount the reverse idle gear and 2 washers to the reverse idle gear shaft.

Tightening torque: 9 - 13 N-m (90 - 130 cm-kg, 78 - 113 in-lb)

2. Install the washer, reverse gear and counter reverse gear.




3. Install the reverse idle gear shaft in the bearing housing.
4. Install the thrust washer, reverse idle gear, adjust washer and secure with the snap ring.
5. Measure the clearance between the adjust washer and snap ring.
6. If the clearance is not as specified, adjust with an adjust washer.

Standard clearance: 0.1 mm (0.004 in) max.
Adjust washer thickness:
2.1 mm (0.083 in), 2.2 mm (0.087 in)
2.3 mm (0.091 in), 2.4 mm (0.094 in)




Mainshaft Lock Nut
1. Install the clutch hub assembly and reverse idle gear.
2. Shift the clutch hub sleeves to first gear and reverse gear to put the gears in the double-engaged condition.




3. Secure the bearing housing in a vise.
4. Tighten the new lock nut using the lock nut wrench (49 1243 465A).

Tightening torque: 130 - 210 N-m (13 - 21 m-kg, 94 - 152 ft-lb)

5. Stake the lock nut.




5th Gear
1. Install the 5th gear and synchronizer ring.
2. Insert the ball and thrust lock washer.
3. Install the "C" washers and hold them with the retaining ring.

CAUTION:
a. Use the 3.0 mm (0.118 in) "C" washers, or else the rear "C" washer may not be able to be installed.
b. The two "C" washers must be the same thickness; a difference in thickness will cause bearing failure.




4. Measure the clearance between the thrust lock washer and "C" washers (5th gear end pay).
If the end play is not as specified, adjust with a thrust lock washer.

Standard play: 0.1 - 0.3 mm (0.004 - 0.012 in)
Thrust lock washer thickness:
6.4 mm (0.252 in)
6.5 mm (0.256 in)
6.6 mm (0.260 in)
6.7 mm (0.264 in)




Bearing
1. Drive on the main drive gear bearing using the lock nut wrench (49 1243 465A), then install the "C" washers, retaining ring and washer and secure them with the snap ring.




2. Measure the clearance between the 'C" washers and washer. If end play is not as specified, adjust the end play with other "C" washers.

Standard play: 0.3 mm (0.012 in) max.
"C" washer thickness:
2.9 mm (0.114 in), 3.0 mm (0.118 in)
3.1 mm (0.122 in), 3.2 mm (0.126 in)

CAUTION: Check that there is no clearance between the bearing and "C" washers.




3. Drive the ball bearing on the counter shaft using the bearing installer (49 0500 330).




Countershaft Lock Nut
1. Shift the clutch hub sleeves to first gear and reverse gear to put the gears in the double-engaged condition.
1. Install the mainshaft holder (49 0259 440) on the mainshaft, and place in a vise
2. Tighten the lock nut.

Tightening torque: 127 - 196 N-m (13 - 20 m-kg, 94 - 145 ft-lb)




Shift Fork and Rod
1. insert the spring and ball (5th/reverse) into the bearing housing.

NOTE: There are 2 types of springs; be sure to install them correctly.




2. Press the spring and ball (5th/reverse) using the interlock pin guide (49 0187 451 A) and a flat-tip screwdriver to install the shift rod.




3. Install the shift rod in the bearing housing.




4. Position the interlock pin in the bearing housing using the shift fork guide (49 0862 350) and interlock pin guide (49 0187 451A).




5. Check that the interlock pin Is correctly installed.




6. Install the shift fork and rod (3rd/4th), and install the interlock pin in the bearing housing as in step 4.
7. Install the shift fork and rod (1st/2nd), the springs balls, and the caps.




8. Install the spring pins in the shift forks.

CAUTION: The spring pin should be installed so the groove of the pin is as shown in the image.




Adjustment of Shift Fork and Clutch Hub Sleeve
1. To obtain the correct position of the shift fork to the clutch hub sleeve, select the proper thrust washer for between 1st gear and the mainshaft bearing, or reverse gear and the mainshaft bearing.







2. The following thrust washer thicknesses are available for use.




Intermediate Housing
1. Coat the intermediate housing mounting surfaces with sealant.
2. Mount the intermediate housing to the bearing housing by tapping lightly with plastic hammer.




Rod End
Install the shift rod ends on the shift rods.

Speedometer Drive Gear
1. Install the snap ring.
2. Mount the ball and speedometer drive gear, and secure them with a snap ring.




Transmission Case
1. Coat the mounting surfaces of the transmission case and bearing housing with sealant.
2. Mount the transmission case to the bearing housing by tapping lightly with a plastic hammer.




Extension Housing
1. Coat the mounting surfaces of the extension housing and intermediate housing with sealant.
2. Shift the clutch hub sleeves to 1st gear.
3. Turn the control rod in the direction of the arrow and install the extension housing.
4. Tighten the bolts.

Tightening torque: 16 - 23 N-m (1.6 - 2.3 m-kg, 12 - 17 ft-lb)




Bearing
1. Drive the main drive shaft bearing on using bearing installer (49 0500 330) and secure with the two snap rings.




2. Drive the counter shaft bearing on using bearing installer (49 0180 321A).




Front Cover
1. After measuring dimensions (A) and (B), use an adjust shim(s), of a thickness corresponding to the value of (A) minus (B), so that bearing end play will be within the specification.

Bearing end play: 0 - 0.1 mm (0 - 0.004 in)
Adjust shim thickness:
0.15 mm (0.006 in)
0.30 mm (0.012 in)




2. Install the front cover.

Tightening torque: 19 - 26 N-m (1.9 - 2.6 m-kg, 14 - 19 ft-lb)




Release Fork
1. Apply molybdenum disulphide grease to the parts of the release bearing and release fork indicated by the shaded lines in the image.
2. Install the release bearing and release fork.




Select Lock Spindle
1. Install the select lock spindle, spring and spring cap.
2. Push the select lock spindle down by pushing on the control rod.
Insert the ball and spring, and install the spring cap.