Part 2

ASSEMBLY (continued)
Case Components
1. Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft assembly. Refer to "Gear Components".
2. Install fork rods and shift forks. Refer to "Shift Control Components".





3. Install oil gutter to transmission case.





4. Install counter front bearing to transmission case.

CAUTION: Apply multi-purpose grease to counter front bearing.





5. Apply recommended sealant to mating surface of transmission case as shown in the figure.
^ Use Genuine Silicone RTV or the equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.





6. Install transmission case to adapter plate assembly.





7. Install snap ring to main drive gear bearing using a snap ring pliers.

CAUTION: Do not reuse snap ring.





8. Tighten baffle plate mounting nut to the specified torque. Refer to "Case Components".





9. Tighten baffle plate mounting bolt to the specified torque. Refer to "Case Components".





10. Install front cover oil seal to front cover using the drift.
Dimension A: 8.55 - 9.55 (0.336 - 0.376 inch)

CAUTION:
^ Do not reuse front cover oil seal.
^ Apply multi-purpose grease onto oil seal lip.
^ When installing, do not incline front cover oil seal.

11. Install front cover according to the following.





a. Install front cover gasket and front cover to transmission case.

CAUTION: Do not reuse front cover gasket.

b. Temporary tightening 2 bolts in the positions shown in the figure.
c. Temporary tightening remaining 9 bolts.





d. Tighten bolts to the specified torque in order as shown on the figure. Refer to "Case Components".

CAUTION: Do not reuse bolts indicated as A in the figure.





12. Install washer to withdrawal lever ball pin, and then install it to front cover. Tighten withdrawal lever ball pin to the specified torque. Refer to "Case Components".





13. Install counter end bearing to rear extension (or OD gear case) using a suitable drift [32 mm (1.26 inch) dia.].
Dimension A: 0.5 - 1.5 (0.020 - 0.059 inch)

CAUTION:
^ Do not reuse counter end bearing.
^ Apply gear oil to counter end bearing.
^ Install counter end bearing with maker stamp at upper side.





14. Install rear extension oil gutter according to the following. (For 2WD models)
a. Install cap to rear extension oil gutter.
b. Install rear extension oil gutter to rear extension, and then tighten mounting bolt to specified torque. Refer to "Case Components".





15. Install rear oil seal to rear extension (or OD gear case) using the drift.
Dimension A
2WD models: 1.2 - 2.2 mm (0.047 - 0.087 inch)
4WD models: -0.5 - 0.5 mm (-0.020 - 0.020 inch)

CAUTION:
^ Do not reuse rear oil seal.
^ Apply multi-purpose grease onto oil seal lip.
^ When installing, do not incline rear oil seal.





16. Install dust seal to rear extension using the drift. (For 2WD models)
Dimension A: 0.5 - 1.5 mm (0.020 - 0.059 inch)

CAUTION:
^ Do not reuse dust seal.
^ Apply multi-purpose grease onto dust seal lip.
^ When installing, do not incline dust seal.





17. Apply recommended sealant to mating surface of rear extension as shown in the figure.
^ Use Genuine Silicone RTV or the equivalent. Refer to "Recommended Chemical Products and Sealants".

CAUTION: Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.





18. Install rear extension (or OD gear case) to adapter plate, and then tighten mounting bolts to the specified torque in order as shown on the figure. Refer to "Case Components".





19. Install check shift pin and pivot bolt to transmission case, and then tighten them to the specified torque. Refer to "Case Components".

CAUTION: Do not reuse check shift pin and pivot bolt.





20. Install return spring plunger, return spring and return spring plug to rear extension (or OD gear case), and then tighten return spring plug to the specified torque. Refer to "Shift Control Components".

CAUTION:
^ Do not reuse return spring plug.
^ Apply gear oil to return spring plunger.





21. Install PNP switch and back-up lamp switch according to the following.
a. Install plunger to rear extension (or OD gear case).
b. Apply recommended sealant to threads of PNP switch and back-up lamp switch.
^ Use Genuine Silicone RTV or the equivalent. Refer to "Recommended Chemical Products and Sealants".
c. Install PNP switch and back-up lamp switch to rear extension (or OD gear case), and tighten them to the specified torque. Refer to "Case Components".





22. Install clips to PNP switch and back-up lamp switch.





23. Install striking arm according to the following.
a. Install striking arm to striking rod assembly.
b. Install retaining pin to striking arm using a pin punch.

CAUTION: Do not reuse retaining pin.





24. Install control housing according to the following.
a. Install gasket and control housing to rear extension (or OD gear case).

CAUTION: Do not reuse gasket.

b. Tighten mounting bolts to the specified torque in order as shown on the figure. Refer to "Case Components".





25. Install gasket to drain plug, and then install it to transmission case. Tighten drain plug to the specified torque. Refer to "Case Components".

CAUTION: Do not reuse gasket.





26. Install gasket to filler plug, and then install it to transmission case. Tighten filler plug to the specified torque. Refer to "Case Components".

CAUTION:
^ Do not reuse gasket.
^ After oil is filled, tighten filler plug to specified torque.