Assembly

ASSEMBLY NOTE
Clutch Hub

NOTE:




a. The synchronizer rings all have the same basic shape; therefore, be careful to select the correct ones.
- The 5th and reverse synchronizer rings are the smallest.
- The 5th has notches in the teeth.
- The 4th and 3rd are the next size up and are exactly the same.
- The 2nd and 1st are the biggest and are exactly the same.







b. There are two types of synchronizer key. Standard dimensions are as follows.




c. Press each clutch hub assembly onto the mainshaft in the proper direction.
d. Install the clutch hubs with the chamfer of the inner gear teeth as shown.






CAUTION: Align the synchronizer ring groove and clutch hub key during installation.




1. Place the 2nd gear and 1st/2nd clutch hub assembly, and press in the mainshaft.




2. Place the 3rd gear, needle bearing and 3rd/4th clutch hub assembly, press the 3rd/4th clutch hub assembly using body (49 F401 331).




3. Insert the snap ring to the front of the mainshaft using snap ring pliers.




4. Install the inner race, needle bearing, 1st gear and thrust washer.




Countershaft
Press the inner race of the countershaft rear bearing onto the countershaft, using the body (49 F401 331) and attachment A (49 F401 335A).




Measurement of Bearing Thrust Play Mainshaft center bearing
1. Measure the depth of the main shaft center bearing bore in the transmission case.




2. Measure the mainshaft center bearing snap ring height. The difference between the two measurements indicates the required thickness of the adjusting shim.

Standard thrust play: 0 - 0.1 mm (0 - 0.004 in)
Adjusting shim thickness: 0.1 mm (0.004 in), 0.3 mm (0.012 in)




Countershaft front bearing
1. Measure the depth (B) of the countershaft front bearing bore in the transmission case and the countershaft front bearing height (A).
2. The difference between the two measurements indicates the required thickness of the adjust shim.

(A) - (B) + Adjust shim(s) = 0.9 - 1.0 mm (0.035 - 0.039 in)
Standard installed bearing height: 0.9 - 1.0 mm (0.035 - 0.039 in)
Adjust shim thickness: 0.1 mm (0.004 in), 0.3 mm (0.012 in)




Transmission Case
1. Position the 1st and 2nd shift forks and the 3rd and
4th shift forks in the grooves of the clutch hub and sleeve assemblies.
2. Install the needle bearing and main drive gear on the front of the mainshaft.

NOTE: Check that the friction gear engages the main drive gear.




3. Position the countershaft gear in the case, making sure that the countershaft gears engage each gear of the mainshaft assembly.

NOTE: Check that the friction gear engages the main drive gear.




Bearing for Transmission Case
1. Install the correct shim on the rear of the mainshaft as determined in the measurement of bearing thrust play.
2. Drive on the mainshaft bearing using a suitable pipe.




3. Drive the countershaft center bearing onto the rear of the countershaft using body (49 F401 331) and attachment A (49 F401 335A).




4. Install the bearing cover.

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




5. Install the synchronizer ring holder (49 F017 101) between the 4th synchronizer ring and synchromesh gear on the main drive gear.




6. Drive on the main drive gear bearing using transmission bearing installer (49 0500 330).




7. Install the snap ring to secure the main drive gear bearing.




8. Install the correct shim in the countershaft front bearing bore as determined by the measurement of bearing thrust play.
9. Drive on the countershaft front bearing using body (49 F401 331) and attachment A (49 F401 335A).




10. Install the snap ring to secure the countershaft front bearing.

NOTE: Do not confuse the front and rear bearing snap rings. The front snap ring is smaller.




Reverse Gear
1. Install the reverse idle gear and shaft with a spacer on each side of the gear.
2. Install the counter-reverse gear (chamfer side forward) and spacer.
3. Install the thrust washer, reverse gear, inner race, needle bearing, and clutch hub assembly.




4. Shift into 1st gear and reverse gear to lock the rotation of the mainshaft.
5. Install a new locknut and tighten it with the main shaft locknut wrench (49 1243 465A).

Tightening torque: 157 - 235 N-m (16 - 24 m-kg, 116 - 174 ft-lb)




6. Check the clearance between the synchronizer key and the exposed edge of the synchronizer ring. If the clearance is not within specification, select the thrust washer between the mainshaft center bearing and the first gear.

Standard: 0.66 - 2.0 mm (0.026 - 0.079 in)
Available thrust washer thickness:
2.5 mm (0.098 in), 3.0 mm (0.118 in), 3.5 mm (0.138 in)




7. Stake the lock nut into the main drive gear keyway.




5th Gear
1. Install the synchronizer ring and 5th gear.
2. Install the steel ball and thrust washer.
3. Install 3.0 mm (0.118 in) thick "C" washers and hold them with the retaining ring.




4. Measure the clearance between the C washers and thrust washer.
If it is not as specified, select another thrust washer.

Standard: 0.1 - 0.2 mm (0.004 - 0.008 in)
Available thrust 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)




Shift Fork and Rod

NOTE: A simple way to identify the shift rods is the following:
- The 3rd/4th shift rod is the longest.
- The 5th/Rev shift rod has an extra hole for the shift fork at the rear of the rod.

When installing the shift rods, set the detents toward the ball side.




Shift Fork and Rod
1. Slide the 1St and 2nd shift rod into the case.
2. Secure the 1st and 2nd shift forks to the rod with the spring pin.

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






NOTE: Insert the interlock pin into the transmission case correctly.




3. Slide the shift fork guide (49 0862 350) into the transmission case, insert the inter-lock pin using interlock pin guide (49 0187 451 A).
4. Slide the 3rd and 4th shift rod into the transmission case.
5. Secure the 3rd and 4th shift rod to the fork with spring pin.
Insert the interlock pin.




6. Install the reverse and 5th fork on the clutch hub and slide the reverse and 5th shift rod into the transmission case.
7. Secure the reverse and 5th shift fork to the shift rod with the spring pin.




8. Install the two blind covers and gaskets.

Tightening torque: 7.8 - 11.8 N-m (0.8 -1.2 m-kg, 5.8 - 8.7 ft-lb)

9. Install the three detent balls, springs and cap bolts.

Tightening torque:
(A) 39 - 59 N-m (4.0 - 6.0 m-kg, 29 - 43 ft-lb)
(B) 19 - 26 N-m (1.9 - 2.7 m-kg, 14 - 20 ft-lb)




Center Housing
1. Coat the contact surfaces of the transmission case and center housing with sealant.
2. Install the center housing.
Align the reverse idle gear shaft boss with the center housing attaching bolt boss, and tighten the bolt.

Tightening torque: 8.8 - 13.7 N-m (0.9 - 1.4 m-kg, 6.5 - 10.1 ft-lb)




3. Install the spacer and counter 5th gear.




Rear Bearing
1. Drive on the countershaft rear bearing using body (49 F401 331) and attachment A (49 F401 335A).




2. Shift into 1st gear and reverse gear to lock the rotation of the countershaft.
3. Install the countershaft lock nut.

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

4. Stake the lock nut into the countershaft keyway.




5. Drive on the mainshaft rear bearing using a suitable pipe.




6. Install the "C" washers and hold them with the retaining ring.
7. Measure the clearance between the "C" washers and groove.
If the clearance is not within specification, select the proper "C" washers.

Standard: 0 - 0.1 mm (0 - 0.0039 in)
Available "C" washers thickness:
2.9 mm (0.1142 in), 3.0 mm (0.1181 in)
3.1 mm (0.1220 in), 3.2 mm (0.1260 in)




Bearing Housing
1. Coat the contacting surfaces of the center housing and bearing housing with sealant.
2. Install the bearing housing on the center housing.




Shift Rod End
Install the shift rod ends onto the proper shift rods, and secure with spring pins.




Speedometer Drive Gear
1. Install the snap ring and key.
2. Install the speedometer drive gear and snap ring.




Measurement of Bearing Thrust Play
Main drive gear bearing
1. Measure the depth of the main drive gear bearing bore in the clutch housing using vernier calipers.




2. Measure the main drive gear bearing height.
The difference between the two measurements indicates the required thickness of the adjust shim.

Standard thrust play: 0 - 0.1 mm (0 - 0.004 in)
Adjust shim thickness: 0.1 mm (0.004 in), 0.3 mm (0.012 in)

NOTE: Make this measurement after assembling the transmission case.




Clutch Housing
1. Coat the contact surfaces of the clutch housing and center housing with sealant.
2. Install the correct shim on the main drive gear bearing and countershaft front bearing as determined in the Measurement of Thrust Play.
3. Tighten the bolts.

Tightening torque: 31 - 46 N-m (3.2 - 4.7 m-kg, 23 - 34 ft-lb)




Extension Housing
1. Coal the contact surfaces of the extension housing and bearing housing with sealant.
2. Turn the control rod in the direction of the arrow and install the extension housing.
3. Tighten the bolts.

Tightening torque: 31 - 46 N-m (3.2 - 4.7 m-kg, 23 - 34 ft-lb)




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.

NOTE: If the select lock spindle is not pushed down, the ball will not correctly engage the select lock spindle.




Under Cover
Install the gasket and under cover.

Tightening torque: 6 - 9 N-m (0.6 - 0.9 m-kg, 4 - 7 ft-lb)




Release Fork
1. Apply a coat of 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.