Extension Housing Assembly
Extension Housing AssemblyComponent Identification: Extension Housing Assembly
1. Install a new speedometer gear Snap- Ring
Optional
2. If you removed the index ball for the speed sensor gear, install the Steel Ball
3. Install the Speedometer Drive Gear
4. Install a new speedometer gear Snap-Ring
5. Install a new Oil Seal into the extension housing using SST 49- G030-797 and 49-B025-001
- Apply Molybdenum Sulfide grease to the seal
Optional
6. If you are replacing the bushing
- Install the new bushing using a hammer and SST 49- N017-001
Optional
7. If you are replacing the Plug
- Install a new plug using a round bar and a hammer
Optional
8. If you removed the Baffle Plate
- Squeeze the baffle plate with pliers
- Install it all the way into the housing
- Make sure the gap in the baffle aligns with the breather hole as pictured
Optional
9. If you removed the Breather
- Install a new breather
Optional
10. If you removed the Lever Support
- Install the lever support into the housing
- Install the bolt on the driver side of the extension housing (12mm)
- Torque the bolt 17 to 23 Nm (13 to 17 ftlb)
Optional
11. If you removed the Oil Funnel
- Press the funnel back into position
Optional
12. If you removed the Stopper Block
- Install the Stopper Block and bolts (two- 12mm)
- Torque the bolts 17 to 24 Nm (13 to 18 ftlb)
Optional
13. If you removed the Oil Pass
- Install the oil pass (10mm)
- Torque it 5.9 to 10.7Nm (53 to 95 inlb)
14. Get the Control Rod, control lever and bolt either:
- In pieces if you took them apart
Or
- Together
Optional
15. Place the Control Lever on the Control Rod
- Apply red loctite to the bolt (12mm)
- Torque the bolt 32 to 45 Nm (24 to 33ftlb)
Combine Step 16 to 18
16. Place the Torsion Spring onto the Control Lever with its E-clip
- Install the Spring onto the Control Lever Using the illustrations
17. Shift Rod and Shift Lever (Combined in Step#16)
18. Retaining Ring(E-clip) (Combined in Step #16)
19. Stand the transmission on the clutch housing
- Apply sealant to the Transmission Case
(The case must be installed in less than 15 minutes. If the sealant hardens, it will not provide a good seal)
20. Get the Control Rod End
- Install the Control Rod End and the Extension Housing
- Install the extension housing bolts (eight-12mm)
- The wire holders go on the top 2-bolts
- Torque the bolts 24 to 35 Nm (18 to 26 ftlb)
- Apply red loctite to the set bolt for the control rod end
- Torque the set bolt 32 to 45 Nm (25 to 33 ftlb)
21. Place a new control case Gasket onto the housing
22. Install the Control Case bolts (four- 12mm)
- Torque them 13.8 to 25.4 Nm (122 to 225 inlb)
23. Install the Backup Light Switch (27 mm) with a new seal
- Torque the switch 35 to 44 Nm (26 to 32 ftlb)
24. Install the Neutral Switch (27 mm)
- Torque the switch 30 to 39 Nm (22 to 28 ftlb)
25. Install the Speedometer Sensor, its bolt (10mm) and a new 0-Ring
- Torque the bolt 7.9 to 10.7 Nm (70 to 95 inlb)
26. Install the Drain Plug and a new Gasket
- Torque it 27 to 48 Nm (20 to 35 ftlb)
27. Install the Filler Plug and new Gasket (finger tight)
28. Place the Clutch Release Bearing onto the Shift Fork
- Apply Molybdenum Sulfide grease to the inside of the bearing and to the shift fork
29. Install the Pivot Pin if you removed it (17mm deep socket)
- Torque it 35 to 44 Nm (26 to 32 ftlb)
- Apply Molybdenum Sulfide grease to the ball
30. Install the Shift Fork Dust Cover
31. Install the Clutch Release Fork and release bearing
Fill the Transmission With Lubricant
Fill the transmission with 1.75L (1.85 qt) of A.P.I. GL-4 or GL-5:
- Torque the fill plug 27 to 48 Nm (20 to 35 ftlb)