Gear: Service and Repair

Assemble in the reverse order of disassembly, referring to the Assembly Note.




Assembly note
Reverse gear
1. Install the reverse idler 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, synchronizer ring, 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 SST.

Tightening torque: 128 - 196 N-m (13 - 20 m-kg, 94 - 145 ft-lb)

CAUTION: The total combined thickness of the front and rear thrust washers must equal 6.0 mm (0.236 in).




6. Check the clearance between the synchronizer key and the exposed edge of the synchronizer ring. If it is not as specified, adjust with the thrust washers on the front and rear of the mainshaft front bearing.

Clearance: 2.0 mm (0.079 in) max.
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 locknut into the mainshaft groove.




5th gear
1. Install the retaining ring to the 5th gear.




2. Install the synchronizer ring, 5th gear, and needle bearing.
3. Install the steel ball and thrust lock washer.
4. Install the 3.0 mm (0.118 in) C-washers and hold them with the retaining ring.




5. Push the C washers toward 5th gear and measure the clearance between the C washers and thrust lock washer.

If the clearance is not as specified, select the proper thrust lock washer.

Standard: 0.1 - 0.2 mm (0.004 - 0.008 in)
Available thrust lock washer thickness:
6.2 mm (0.244 in), 6.3 mm (0.248 in)
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 as follows:
- The 3rd/4th shift rod is the longest.
- The 5th/Reverse 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.

CAUTION: The roll pin must be Installed with the split as shown.




1. Slide the 1st/2nd shift rod into the case.
2. Secure the 1st/2nd shift fork to the rod with the new roll pin.






NOTE: The Interlock pins must be installed as shown.




3. Slide the two SST into the transmission case to guide the interlock pins, and insert the first pin.
4. Remove the 3rd/4th shift fork guide from the case.
5. Slide the 3rd/4th shift rod into the case.
6. Secure the 3rd/4th shift rod onto the fork with the new roll pin.
7. Insert the remaining interlock pin and remove the SST.




8. Install the 5th/Reverse shift rod.
9. Secure the 5th/Reverse shift fork onto the shift rod with a new roll pin.
10. Install new clips onto the 1st/2nd shift rod and 3rd/4th shift rod.




11. Install the two blind covers and gaskets.

Tightening torque: 7.8 - 12 N-m (80 - 120 cm-kg, 69 - 104 in-lb)

12. Install the packings, 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 - 25 N-m (1.9 - 2.6 m-kg, 14 - 19 ft-lb)




Center housing
1. Apply sealant to the contact surfaces of the transmission case and center housing.
2. Install the center housing.
Align the reverse idler gear shaft with the set bolt hole; then install the set bolt and gasket.

Tightening torque: 19 - 25 N-m (1.9 - 2.6 m-kg, 14 - 19 ft-lb)




3. Install the oil guide.

Tightening torque: 7.8 - 11 N-m (80 - 110 cm-kg, 69 - 95 in-lb)




4. Install the spacer and counter 5th gear.




Rear Bearing
1. Drive on the countershaft rear bearing with the SST.

NOTE: Use the protective plates to prevent damage to the SST.




2. Connect the SST to the mainshaft and mount it securely in a vise.
3. Shift into 1st gear and reverse gear to lock the countershaft.
4. Install the new countershaft locknut.

Tightening torque: 128 - 196 N-m (13 - 20 m-kg, 94 - 145 ft-lb)




5. Stake the locknut into the countershaft groove.




6. Drive on the mainshaft rear bearing with a suitable pipe.




7. Install the C-washers and hold them in place with the retaining ring.
8. Measure the clearance between the C-washers and the groove.
If the clearance is not as specified, select the proper C-washers.

Standard: 0 - 0.1 mm (0 - 0.004 in)
Available C-washer thicknesses:
2.9 mm (0.114 in), 3.0 mm (0.118 in)
3.1 mm (0.122 in), 3.2 mm (0.126 in)




Bearing housing
1. Apply sealant to the contact surfaces of the center housing and bearing housing.
2. Install the bearing housing onto the center housing.




Shift rod end
Install the shift rod ends onto the proper shift rods, and secure them with new roll pins.