Assembly

1. Install striking lever and striking rod.




2. Install selector and retaining pin.




3. Install reverse gate assembly.




4. Install final drive assembly.




5. Install input shaft and mainshaft with 1st & 2nd shift fork assembly.

Note: Be careful not to damage input shaft oil seal.




6. Install interlock balls and plunger.







7. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th shift rod, stopper ring and retaining pin.

Note: When installing stopper ring, use snap ring remover and installer (J34305).




8. Install interlock balls.




9. Install 5th shift fork and bracket, then install shift rod, stopper ring and retaining pin.

Note: When installing stopper ring, use snap ring remover and installer (J34305).




10. Install 5th & reverse check plug, spring and ball.







11. Install reverse lever assembly.

Note: Apply multi-purpose grease to check ball.




12. Install reverse arm shaft and retaining pin.




13. Mesh 4th gear. Then install reverse idler gear and shaft, paying attention to the direction of the tapped hole.




14. Place magnet on clutch housing.




15. If bearing preload was adjusted, install selected shim(s) into transmission case.

Note: To aid in installation of the transmission case, place the shift selector in the 1st and 2nd shift bracket or between the 1st and 2nd bracket and the 3rd and 4th bracket.

16. Apply sealant to mating surface of transmission case and install it.
17. Install position switch.





18. Apply sealant to threads of check plugs. Install balls, springs and plugs.
19. After assembly, check that you can shift into each gear smoothly.




20. Measure total turning torque.

Total turning torque (New bearing): 8.8 - 21.6 N.m (90 - 220 kg-cm, 78 - 191 in-lb)

Note: When old bearing is used again, preload will be slightly lower than that indicated above. Check preload to see if it is not far from specified range.