Clutch Housing Assembly
Clutch Housing AssemblyComponent Identification: Clutch Housing, Shift Fork, and Shift Rod Assembly
Apply transmission lubricant to all parts as they are assembled
Optional
If you disassembled the shift arm, assemble the 1st / 2nd / 5th/ Rev Shift Rod
Combine Step 1 thru 4
1. Get the Shift Rod
2. Place the 1st / 2nd Shift Fork on the shift rod
3. Place the Interlock Sleeve on the shift rod
4. Place the 5th/Reverse Shift Fork on the shift rod
Optional
If you disassembled the Reverse Idler Gear:
Combine Step 5 thru 10
5. Get the Reverse Idler Gear
Optional
6. Install the Torsion Spring into the large hole in the idler gear
Optional
7. Install the Friction Gear
- The spring goes through the large hole
Optional
8. Install the split Spacer
Optional
9. If you removed the Snap-Ring, Install a new Snap- Ring
10. Tension the Reverse Idler Gear
- Turn the friction gear counter-clockwise by hand
- Align the reverse idler gear hole with the friction gear hole
- Insert SST 49-N017-204 through the holes in the gear and friction plate
11. Tension the Countershaft Drive Gear Friction Plate
- Turn the friction gear using SST 49- N017-202 and SST 49-N017-203
- Align the hole in the drive gear with the hole in the friction gear
- Insert SST 49-N017-201 into the hole from the counter drive gear side to secure the friction gear
12. Install the Reverse Idler Shaft into reverse gear
Assemble the Shafts to the Clutch Housing
Combine Step 13 thru 15
13. Assemble all of the shafts to the clutch housing at the same time
14. Get the Main drive gear and Mainshaft
15. Get the shift fork and shift rod assembly 15A. Get the 3rd/4th shift fork {part #22}
- All the pieces must be inserted into the clutch housing at the same time
- Lay the pieces out together on the bench and tie them together with a plastic tie strap
- Place the 3rd/4th shift fork onto the 3rd/4th sleeve and secure it with a plastic tie strap
- Place the shafts and rods into the clutch housing
- Place the reverse idler gear into position in the housing
- Place the reverse idler shaft into the housing
- Adjust the position of the shafts until they are all aligned with their holes
- Cut the plastic tie straps after all components are properly installed
- Remove both of the SSTs holding the friction gears
16. Install a reverse idler shaft bolt with a new gasket into the clutch housing
- Only finger tighten the bolt. Do not tighten the bolt with a wrench at this time,
Optional
(I you disassembled the 3rd/4th Shift Arm) Assemble the 3rd/4th Shift Arm
Combine Step 17 thru 21
17. Get the 5th shift arm
Optional
18. Install the steel ball and correct pressure spring into the 5th shift arm
Optional
19. Use a punch to compress the ball and spring
- Insert the 5th shift arm onto the shift rod
Optional
20. Place the Stopper Block onto the shift rod
Optional
21. Install a new spring-pin into the Stopper Block
22. Place the Reverse Shift Arm into the clutch housing
- Place the 3rd / 4th shift rod through the 3rd /4th Shift Sleeve
23. Pass the shift rod through the reverse shift arm
24. Brace the shift rod and drive a new spring-pin into the Reverse Shift Arm
Combine Step 25 & 26
25. Install the 5th / Reverse Counter Lever
26. Install the Crank Lever Shaft (8mm-Hex)
- Apply sealant to the threads of the fastener
- Torque the fastener 32 to 47Nm (24 to 34 /ftlb)