Assembly
1. Counter reverse gear
2. Thrust washer
3. Reverse idler gear
4. Reverse idler gear shaft
5. Thrust washer
6. Thrust washer
7. Bearing race
8. Bearing
9. Reverse gear
10. Synchronizer ring (Reverse)
11. 5th/Reverse clutch hub assembly
12. Locknut
13. Synchronizer ring (5th)
14. Retaining ring
15. 5th gear
16. Bearing
17. Steel ball
18. Thrust lock washer
19. C-washers and retaining ring
20. 1st/2nd shift rod
21. Interlock pin (large)
22. Interlock pin (small)
23. 3rd/4th shift rod
24. Interlock pin (large)
25. 5th/Reverse shift fork
26. Spring
27. 5th/Reverse shift rod
28. Retaining ring
29. Cap plug, spring, and detent ball
30. Blind cover
31. Oil guide
32. Center housing
33. Set bolt and washer
34. Spacer
35. Counter 5th gear
36. Countershaft rear bearing
37. Locknut
38. Mainshaft rear bearing
39. Retaining ring
40. C-washers
41. Thrust washer
42. Snap ring
43. Bearing housing
44. 1st/2nd shift rod end
45. 3rd/4th shift rod end
46. 5th/Reverse shift rod end
47. Oil guide
Assemble in the order shown, referring to Assembly Note.
Assembly note
Synchronizer ring (5th/Reverse)
The 5th and Reverse synchronizer rings are differentiated as follows.
1. The 5th synchronizer ring has 3 places on its circumference with one tooth missing in each place.
2. The Reverse synchronizer ring has no distinguishing marks.
5th/Reverse clutch hub assembly and locknut
CAUTION: Align the 5th/Reverse synchronizer grooves with the synchronizer keys.
NOTE: Standard key dimensions are as above.
CAUTION: Install the 5th/Reverse clutch hub assembly in the proper direction as shown.
1. Shift the clutch hubs into 1st and 4th gears to lock the rotation of the mainshaft.
2. Install a new locknut and tighten it with the SST.
Tightening torque: 157 - 235 N-m (16.0 - 24.0 kgf-m, 116 - 173 ft-lbf)
CAUTION: The total combined thickness of the front and rear thrust washers must equal 6.0 mm (0.236 in).
3. Check the clearance between the synchronizer key and the exposed edge of the synchronizer ring.
If it is not as specified, adjust by changing the thrust washers on the front and rear of the mainshaft front bearing.
Clearance: 0.6 - 2.0 mm (0.026 - 0.079 in)
Available thrust washer thicknesses: 2.5 mm (0.098 in), 3.0 mm (0.118 in), 3.5 mm (0.138 in)
4. Stake the locknut into the mainshaft groove.
5th gear
1. Install a new 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 a 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 thicknesses:
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), 6.1 mm (0.264 in)
Shift forks and rods
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 roll pin 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 a 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 containing the interlock pin (small) 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 fork onto the clutch hub.
9. Install the 5th/Reverse shift rod in the transmission case through the spring.
10. Push back the spring, and install a new clip to the 5th/Reverse shift rod.
11. Install a new roll pin into the 5th/Reverse shift fork.
12. Install the two blind covers and two new gaskets.
Tightening torque: 7.9 - 10.7 N-m (80 - 110 kgf-cm, 70 - 95.4 in-lbf)
13. Install the packings, detent balls, springs, and cap bolts.
Tightening torque:
A: 40 - 58 N-m (4.0 - 6.0 kgf-m, 29 - 43 ft-lbf)
B: 19 - 25 N-m (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
Center housing
1. Apply sealant to the contact surfaces of the transmission case and center housing.
2. Install the oil guide.
3. Install the center housing.
4. Align the reverse idler gear shaft with the set bolt hole, and install the set bolt and washer.
Tightening torque: 8.9 - 13.7 N-m (90 - 140 kgf-cm, 79 - 121 in-lbf)
5. Install the spacer and counter 5th gear.
Countershaft rear bearing
1. Install the countershaft rear bearing by using the SST.
2. Connect the SST to the mainshaft and mount it securely in a vise.
3. Shift into 1st gear to lock the countershaft.
4. Install the new countershaft locknut.
Tightening torque: 128 - 196 N-m (13.0 - 20.0 kgf-m, 95 - 144 ft-lbf)
5. Stake the locknut into the countershaft groove.
Mainshaft rear bearing
1. Drive on the mainshaft rear bearing with a suitable pipe.
Bearing diameter (inner): 22 mm (0.87 in)
Bearing diameter (outer): 56 mm (2.2 in)
2. Install the C-washers and hold them in place with a new retaining ring.
3. With points A and B pressed tightly together, 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 ends
Install the shift rod ends onto the proper shift rods, and secure them with new roll pins facing as shown in the image.