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 tilling the transmission with transmission oil.
Clutch hub
For the synchronizer assemblies, align the synchronizer ring grooves and synchronizer keys.
The synchronizer rings can be distinguished as shown in the image. The inner diameters of the 2nd synchronizer ring is larger than the 1st.
When installing the gears and clutch hub assemblies in the following procedure, make sure that they are installed in the direction shown in the image.
Extension Housing Parts
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Oil seal
1. Apply the specified oil to a new oil seal.
2. Install the new oil seal by using the SST.
Rod cover
1. Apply transmission oil to the rubber bushings on the rod cover.
2. Install the rod cover with the mark facing forward.
Roll pin
Install a new roll pin into the control rod end. The split in the roll pin must be facing in the direction shown in the image.
Select-lock spindle, spring, and spring cap
1. Install the select-lock spindle, spring, and spring cap.
Tightening torque: 7.9 - 10.7 N-m (80 - 110 kgf-cm, 70 - 95.4 in-lbf)
2. Push the select-lock spindle down by pushing on the control rod. This will ensure that the steel ball correctly engages the select-lock spindle.
Bearing Housing Assembly
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Countershaft center bearing
Press the countershaft center bearing into the bearing housing with a suitable pipe.
Outer diameter of pipe: 50.0 mm (1.97 in)
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.
Outer diameter of pipe: 70.0 mm (2.76 in)
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
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 image referring to Assembly Note.
Assembly note
Clutch hub assembly
1. Set the 2nd gear, 2nd synchronizer ring, and 1st/2nd clutch hub assembly on the mainshaft, then press in the mainshaft.
2. Set the 3rd gear, 3rd synchronizer ring, 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 springs
5. 4th synchronizer ring
6. Bearing
7. Main drive gear
8. Bearing housing assembly
9. Washer
10. Mainshaft gear assembly
11. Spacer
12. Countershaft
13. Counter reverse gear
14. Washer
15. Bearing race
16. Bearing
17. Reverse gear
18. Reverse synchronizer ring
19. Clutch hub assembly (5th/Reverse)
20. Locknut (Mainshaft)
21. 5th synchronizer ring
22. 5th gear
23. Steel ball
24. Thrust lock washer
25. C-washer
26. Retaining ring
27. Spacer
28. Counter 5th gear
29. Mainshaft rear bearing
30. C-washer
31. Retaining ring
32. Washer
33. Snap ring
34. Countershaft rear bearing
35. Locknut (Countershaft)
Assemble in the order shown in the image, 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)
1. Secure the bearing housing assembly in a vise.
2. Shift the clutch hub sleeves into 1st and Reverse gears to lock the rotation of the mainshaft.
3. Install a new locknut and tighten it by using the SST.
Tightening torque: 128 - 235 N-m (13 - 24 kgf-m, 95 - 173 ft-lbf)
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.
4. Push the C-washers fully 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. Install the mainshaft rear bearing by using the SST, and fully seat 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.
4. If the C-washers do not fit into the rear mainshaft groove, select the proper thickness C-washers.
5. Verify that both C-washers at one position are the same thickness.
6. 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
Install 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.
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 image, referring to Assembly Note.
Assembly note
Spring and ball
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 image.
Roll pin
Install a new roll pin into each shift fork. The roll pin must be installed with the split facing as shown.
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 to install between 1st gear and the mainshaft front bearing, and between reverse gear and the mainshaft front bearing.
4. The following washer thicknesses are available. The total thickness of the front and rear washers should be 5.9 - 6.0 mm (0.232 - 0.236 in).
Washer thickness:
2.2 mm (0.087 in), 2.7 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
Install a new roll pin into each shift rod end. The roll pin must be installed with the split facing forward.
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. 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 image, referring to Assembly Note.
2. Check the gearshift lever operation.
Assembly note
Oil seal
1. Apply transmission oil to the 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 891; 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 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 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.