Transmission Case Components
1. Snap ring
2. Steel ball
3. Dynamic damper
4. Taper cotter
5. Locknut
6. Snap ring
7. Snap ring
8. Steel ball
9. Speedometer driven gear
10. Snap ring
11. Transmission case
12. Control lever
13. Control lever end
14. Extension housing
15. Roll pin
16. Main drive gear bearing
17. Snap ring
18. Countershaft front bearing
19. Snap ring
20. Adjustment shim
21. Gasket
22. Front cover
23. Select-lock spindle, spring, and spring cap
24. Steel ball, spring, and spring cap
25. Blind cover
26. Speedometer drive gear
27. Neutral switch
28. Back-up light and 5th switch
29. Boot
30. Release fork
31. Release bearing
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Locknut
1. Install a new snap ring, the steel ball, and the dynamic damper.
2. Set the taper coffers between the mainshaft and dynamic damper.
NOTE: Use pads in the vise to prevent damaging the SST.
3. Connect the SST to the mainshaft and tighten it securely in a vise.
4. Install the locknut with the SST.
Tightening torque (without SST): 157 - 206 N-m (16 - 21 m-kg, 116 - 152 ft-lb)
Tightening torque (with SST):
5. Install a new snap ring to secure the locknut.
Transmission case
1. Apply sealant to the contact surfaces of the bearing housing and transmission case.
2. Mount the transmission case to the bearing housing.
Extension housing
1. Apply sealant to the contact surfaces of the intermediate housing and extension housing.
2. Set the control lever to the shift rod end groove.
3. Set the control lever end into the extension housing, and install the extension housing.
4. Apply sealant to the bolt threads, then install the bolts.
Tightening torque: 16 - 23 N-m (1.6 - 2.3 m-kg, 12 - 17 ft-lb)
CAUTION: The roll pin should be installed so that the seam of the pin face as shown in the image.
5. Install a new roll pin into the control lever end.
Main drive gear bearing
Drive on the main drive gear bearing with the SST, and secure it with a new snap ring.
Countershaft front bearing
Drive on the countershaft front bearing with the SST, and secure it with a new snap ring.
Front cover
1. After measuring dimensions (A) and (B) shown in the image, use an adjustment shim(s), as specified below, of the thickness corresponding to the value of (A) minus (B), so that bearing end play will be within the standard value.
Bearing end play: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim thickness: 0.10 mm (0.004 in), 0.15 mm (0.006 in), 0.30 mm (0.012 in)
2. Install the new gasket and front cover.
Tightening torque: 19 - 25 N-m (1.9 - 2.6 m-kg, 14 - 19 ft-lb)
Select-lock spindle
1. Install the select-lock spindle, spring, and spring cap.
Tightening torque: 7.8 - 11 N-m (80 - 110 cm-kg, 69 - 95 in-lb)
2. Apply sealant to the spring cap threads.
NOTE: If the select-lock spindle is not pushed down, the ball will not correctly engage it.
3. Push the select-lock spindle down by pushing on the control rod.
4. Insert the ball and spring, and install the spring cap.
Tightening torque: 3.9 - 5.9 N-m (40 - 60 cm-kg, 35 - 52 in-lb)
5. Apply sealant to the contact surfaces of the change control case and blind cover.
6. install the blind cover.
Tightening torque: 7.8 - 11 N-m (80 - 110 cm-kg, 69 - 95 in-lb)
Release fork
1. Apply More white TA No.2 or equivalent organic molybdenum grease to the shaded areas of the release bearing and release fork.
2. Install the release bearing and release fork.