Transmission Case Components

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




Assembly note
Clutch housing
1. Measure the depth of the main drive gear bearing bore in the clutch housing with vernier calipers.

NOTE: Make this measurement after assembling the transmission case.




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

Standard thrust play: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim thickness:
0.3 mm (0.012 in), 0.4 mm (0.016 in),
0.5 mm (0.020 in), 0.6 mm (0.024 in),
0.7 mm (0.028 in)




3. Apply oil to the oil seal lip, and install it to the clutch housing with the SST.




4. Apply sealant to the contacting surfaces of the clutch housing and transmission case.
5. Install the correct adjustment shim on the main drive gear bearing.
6. Install the clutch housing.

Tightening torque: 41 - 55 N-m (4.2 - 5.6 m-kg, 30 - 41 ft-lb)




7. Install the front cover on the clutch housing.

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




Locknut
1. Install a new snap ring, the steel ball, and the dynamic damper.




2. Set the taper cotters 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.




Extension housing
1. Apply sealant to the contact surfaces of the extension housing and change control case.
2. Install the change control case.

Tightening torque: 22 - 30 N-m (2.2 - 3.1 m-kg, 16 - 22 ft-lb)




3. Install the oil passage.

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




4. Install the control lever and control rod end.

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.

NOTE: Align the Inner shift lever and shift rod end groove.




6. Apply sealant to the contact surfaces of the extension housing and bearing housing.
7. Turn the control rod in the direction of the arrow and install the extension housing.





8. Apply sealant to the bolt threads, then install the bolts.

Tightening torque:
(A): 41 - 55 N-m (4.2 - 5.6 m-kg, 30 - 41 ft-lb)
(B): 31 - 46 N-m (3.2 - 4.7 m-kg, 23 - 34 ft-lb)

9. Install the select-lock spindle, spring, and spring cap.

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




10. Apply sealant to the spring cap threads.

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

11. Push the select-lock spindle down by pushing on the control rod.
12. 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)




13. Apply sealant to the contact surfaces of the change control case and blind cover.
14. Install the blind cover.

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




Undercover
Install the undercover and a new gasket.

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.