Assembly
Precaution1. All O-rings and gaskets must be replaced with the new ones included in the overhaul kit.
2. Before assembly, make sure all parts are completely clean.
3. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil.
Clutch hub
CAUTION: Align the synchronizer ring grooves with the clutch hub keys during installation.
NOTE:
- The synchronizer rings all have the same basic shape. Carefully note these distinguishing features:
a. 5th and Reverse synchronizer rings are the smallest.
b. The 5th synchronizer ring has 3 places on its circumference with 1 tooth missing in each place.
c. The Reverse synchronizer ring has 3 places on its circumference with 2 teeth missing in each place.
d. 4th and 3rd synchronizer rings are the next larger and are exactly the same.
e. 2nd and 1st synchronizer rings are the largest and are exactly the same.
- Press each clutch hub assembly onto the mainshaft in the proper direction as shown.
- Install the clutch hubs with the chamfers of the inner gear teeth as shown.
Extension Housing Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Oil seal
1. Apply transmission oil to outer periphery.
2. Install a new oil seal with the SST.
Rod cover
1. Apply transmission oil to rubbers on the rod cover.
2. Install the rod cover with the mark facing forward.
Roll pin
CAUTION: Install the roll pin with the seam facing as shown in the figure.
Install a new roll pin into the control lever end.
Select-lock spindle, spring, and spring cap
1. Install the select-lock spindle, spring, and spring cap.
Tightening torque: 7.8 - 10.7 N-m (80 - 110 cm-kg, 70 - 95.4 in-lbf)
NOTE: If the select-lock spindle is not pushed down, the ball will not correctly engage the select-lock spindle.
2. Push the select-lock spindle down by pushing on the control rod.
Bearing Housing Assembly
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Countershaft center bearing
Press the countershaft center bearing into the bearing housing with a suitable pipe.
Adjustment shim
Measure the clearance between the countershaft center bearing and the bearing housing.
If not within specification, adjust the clearance by installing the correct adjustment shim(s).
Standard clearance: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim: 0.1 mm (0.004 in), 0.3 mm (0.012 in)
Mainshaft front bearing
Press the mainshaft front bearing into the bearing housing with a suitable pipe.
Adjustment shim
Measure the clearance between the mainshaft front bearing and the bearing housing.
If not within specification, adjust the clearance by installing the correct adjustment shim(s).
Standard clearance: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim: 0.1 mm (0.004 in), 0.15 mm (0.006 in), 0.3 mm (0.012 in)
Reverse idler gear shaft
1. Press the reverse idler gear shaft into the bearing housing.
2. Install and tighten the reverse idler gear shaft installation bolt.
Tightening torque: 8.9 - 12.7 N-m (90 - 130 kgf-cm, 79 - 112 in-lbf)
Reverse idler gear
NOTE: Install the reverse idler gear, end washer, and bearing cover as an assembly.
1. Install the reverse idler gear, end washer, and bearing cover.
2. Tighten the bearing cover installation bolts.
Tightening torque
(A): 18 - 26 N-m (1.8 - 2.7 kgf-m, 14 - 19 ft-lbf)
(B): 37 - 53 N-m (3.7 - 5.5 kgf-m, 27 - 39 ft-lbf)
Mainshaft Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Clutch hub assembly
1. Set the 2nd gear, synchronizer ring (2nd), and 1st/2nd clutch hub assembly on the mainshaft, then press in the mainshaft.
2. Set the 3rd gear, synchronizer ring (3rd), and 3rd/4th clutch hub assembly on the mainshaft, then press them onto the mainshaft by using the SST.
3. Install a new snap ring on the front of the mainshaft,
4. Install the bearing race, bearing, and 1st gear.
Mainshaft and Countershaft Parts
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer key spring
5. Synchronizer ring (4th)
6. Bearing
7. Main drive gear
8. Bearing housing assembly
9. Washer
10. Mainshaft gear assembly
11. Countershaft
12. Counter reverse gear
13. Washer
14. Bearing race
15. Bearing
16. Reverse gear
17. Synchronizer ring (Reverse)
18. Clutch hub assembly
19. Locknut (Mainshaft)
20. Synchronizer ring (5th)
21. 5th gear
22. Steel ball
23. Thrust lock washer
24. C-washer
25. Retaining ring
26. Spacer
27. Counter 5th gear
28. Mainshaft rear bearing
29. C-washer
30. Retaining ring
31. Washer
32. Snap ring
33. Countershaft rear bearing
34. Locknut (Countershaft)
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Mainshaft and countershaft
1. Place the mainshaft gear assembly and the countershaft on the bearing housing.
2. Use a suitable bar to press in the countershaft
Locknut (Mainshaft)
NOTE: Use pads in the vise to prevent damaging the bearing housing.
1. Secure the bearing housing in a vise.
2. Slide the clutch hub sleeves onto 1st and reverse gears to lock the rotation of mainshaft.
3. Tighten a new locknut with the SST.
Tightening torque: 128 - 235 N-m (13 - 24 m-kg, 95 - 173 ft-lb)
4. Use a chisel to stake the locknut.
Thrust lock washer
1. Install the synchronizer ring and 5th gear.
2. Insert the steel ball and thrust lock washer.
3. Install only the two 3.0 mm (0.118 in) thick C-washers in the front mainshaft groove.
CAUTION: If the C-washer are not pushed fully forward the 5th gear side, the measurement will be incorrect.
4. Push the C-washers toward 5th gear and measure the clearance between the thrust lock washer and C-washers.
If the clearance is not as specified, select the proper thrust lock washer.
Standard play: 0.1 - 0.3 mm (0.004 - 0.012 in)
Thrust lock washer thickness: 6.2 mm (0.244 in), 6.4 mm (0.252 in), 6.5 mm (0.256 in), 6.6 mm (0.260 in)
5. Install the retaining ring.
Mainshaft rear bearing
1. Drive on the mainshaft rear bearing by using the SST, fully seating it against the front C-washers.
2. Install the original C-washers and hold them with the retaining ring.
3. Install the washer and new snap ring.
CAUTION:
- If points (A) through (C) as shown in the figure, are not pressed together tightly, the measurement will be incorrect.
- If the C-washers do not fit into the rear mainshaft groove, select the proper thickness C-washers.
- Verify that both C-washers at one position are the same thickness.
4. With points (A) through (C) pressed tightly together, measure the clearance between the washer and snap ring.
If the clearance is not as specified, select the proper C-washers.
Standard play: 0 - 0.1 mm (0 - 0.004 in)
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)
Countershaft rear bearing
Drive the countershaft rear bearing onto the countershaft by using the SST.
Locknut (Countershaft)
1. Shift the clutch hub sleeves into 1st and Reverse gears to lock the rotation of the mainshaft.
NOTE: Use protective pads in the vise to prevent damaging the SST.
2. Connect the SST to the mainshaft and secure it in a vise.
3. install a new locknut and tighten it.
Tightening torque: 128 - 196 N-m (13 - 20 kgf-m, 95 - 144 ft-lbf)
4. Use a chisel to stake the locknut.
Shift Fork and Shift Rod Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Spring and ball
NOTE: There are 2 types of springs; be sure to install them correctly.
1. Insert the spring and ball (5th/Reverse) into the bearing housing.
2. Press down the spring and ball (5th/Reverse) by using the SST and a screwdriver, and install the shift rod.
Shift fork and rod
Install the 5th/Reverse shift fork and 5th/Reverse shift rod into the bearing housing.
Interlock pin
1. Position the interlock pin into the bearing housing by using the SST.
2. Verify that the interlock pin is correctly installed.
Shift fork and rod, interlock pin
1. Set the 1st/2nd shift fork onto the 1st/2nd clutch hub assembly.
2. Install the 3rd/4th shift fork and 3rd/4th shift rod, and install the interlock pin into the bearing housing as shown in the interlock pin assembly note.
Roll pin
CAUTION: Install the roll pin with the split facing as shown in the figure.
Install a new roll pin into each shift fork.
Spring, spacer, clip
1. Slide the spring and spacer onto the 5th/Reverse shift rod. While pressing the spacer, install a new clip.
2. Install new clips to the 3rd/4th shift rod and 1st/2nd shift rod.
3. Verify that the centers of the shift fork and clutch hub sleeve are aligned properly.
If they are not, select the proper washer for between 1st gear and the mainshaft front bearing, and between reverse gear and the mainshaft front bearing.
CAUTION: The total thickness of the front and rear washers should be 5.9 - 6.0 mm (0.232 - 0.236 in).
4. The following washer thicknesses are available.
Washer thickness:
2.2 mm (0.087 in), 2.1 mm (0.106 in)
3.0 mm (0.118 in), 3.2 mm (0.126 in)
3.7 mm (0.146 in)
Intermediate housing
1. Apply sealant to the contact surfaces of the intermediate housing and bearing housing.
2. Mount the intermediate housing to the bearing housing by tapping it lightly with a plastic hammer.
Roll pin
CAUTION: Install the roll pin with the split facing forward.
Install a new roll pin into each shift rod end.
Housing Components
1. Oil seal
2. Snap ring
3. Steel ball
4. Speedometer drive gear
5. Snap ring
6. Transmission case
7. Extension housing
8. Main drive gear bearing
9. Snap ring
10. Countershaft front bearing
11. Snap ring
12. Adjustment shim
13. Gasket
14. Front cover
15. Speedometer driven gear
16. Park/Neutral switch
17. Back-up light switch
18. Boot
19. Clutch release fork
20. Clutch release collar
1. Assemble in the order shown in the figure, referring to Assembly Note.
2. Check the gearshift lever operation.
Assembly note
Oil seal
1. Apply transmission oil to outer periphery.
2. Install a new oil seal with the SST.
Extension housing
1. Apply sealant to the contact surfaces of the bearing housing and transmission case.
2. Align the inner shift lever and shift rod end groove, and install the extension housing.
3. Apply sealant to the bolt threads, and install the bolts.
Tightening torque: 18 - 26 N-m (1.8 - 2.7 kgf-m, 14 - 19 ft-lbf)
Main drive gear bearing
Install the main drive gear bearing by using the SST, and secure it with a new snap ring.
Countershaft front bearing
Install the countershaft front bearing by using the SST, and secure it with a new snap ring.
Adjustment shim
After measuring dimensions (A) and (B) shown in the figure, 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 specification.
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)
Clutch release fork
1. Apply More White TA No.2 or equivalent organic molybdenum grease to the shaded areas of the clutch release collar and release fork.
2. Install the clutch release collar and clutch release fork.