Assembly

ASSEMBLY
1. Install striking lever and striking rod with Tool.





2. Install selector and retaining pin with Tool.





3. Install reverse gate assembly. Be careful not to lose check ball.





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





8. Install interlock balls.





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





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





11. Install reverse lock spring on 5th & reverse bracket. Pay attention to its direction.





12. Install check ball and reverse lever spring on reverse lever assembly. Apply multi-purpose grease to check ball. Pay attention to direction of reverse lever spring.





13. Install reverse lever assembly on clutch housing.





14. Install reverse arm shaft and retaining pin.





15. Hook reverse lock spring and reverse lever spring on reverse lever assembly.





16. Mesh 4th gear, then install reverse idler gear and shaft. Pay attention to direction of tapped hole.





17. Place magnet on clutch housing.





18. If bearing preload was adjusted, install selected shim(s) into transmission case. To aid in installation of transmission case, place shift selector in the 1st & 2nd shift bracket or between 1st & 2nd bracket and 3rd & 4th bracket.
19. Apply an anaerobic liquid gasket Loctite P/N 51813 or equivalent to mating surface of transmission case and install it.
20. Install position switch.





21. Apply an anaerobic liquid gasket Loctite P/N 51813 or equivalent to threads of check plugs. Install balls, springs and plugs.
22. After assembly, check that you can shift into each gear smoothly.





23. Measure total turning torque.
Total turning torque (New bearing): 8.8 - 21.6 Nm (78 - 191 inch lbs.)

NOTE: When old bearing is used again, preload will be slightly less than the above. Make sure torque is close to the specified range.