Part 2

8. Install steel ball, 4th bushing and 4th main gear.
- Apply multi-purpose grease to steel ball before installing it.
- 4th bushing has a groove in which steel ball fits.





9. Press on 5th main gear.








10. Select proper mainshaft bearing spacer to give correct bearing distance.

Bearing distance "C": 230.15 - 230.25 Nm (9.0610 - 9.0649 inch)

Spacers available: Refer to image.





11. Press on mainshaft rear bearing.





12. Select and install mainshaft C-ring that gives proper clearance of groove in mainshaft.

Allowable clearance of groove: 0 - 0.1 Nm (0 - 0.004 inch)

Mainshaft C-rings: Refer to image.





13. Install C-ring holder and snap ring.
14. Measure gear end play as the final check.

FINAL DRIVE
DISASSEMBLY





1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.





4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.

INSPECTION
Gear, Washer, Shaft and Case





- Check mating surfaces of differential case, side gears and pinion mate gears.
- Check washers for wear.

Bearing





- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.

ASSEMBLY





1. Attach side gear thrust washer to side gear and install both of them in differential case.
2. Install pinion mate washers and pinion mate gears in place.





3. Insert pinion mate shaft.
- When inserting, be careful not to damage pinion mate thrust washers.





4. Measure clearance between side gear and differential case with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection.

Clearance between side gear and differential case with washers: 0.1 - 0.2 Nm (0.004 - 0.008 inch)

c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.





Side gear thrust washers for differential case side: Refer to image.





5. Install retaining pin.
- Make sure that retaining pin is flush with case.





6. Install final gear.
- Apply locking sealant to final gear fixing bolts before installing them.

7. Install speedometer drive gear.





8. Press on differential side bearings.

SHIFT CONTROL COMPONENTS
INSPECTION








- Check contact surface and sliding surface for wear, scratches, projections or other damage.

ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM





1. Install striking lever and rod, striking interlock assembly and control bracket on clutch housing as shown.
- When installing control bracket on clutch housing, assure protrusion beneath bracket is correctly seated.





2. Measure maximum height "H" while shifting from neutral to reverse position.

Maximum height "H": 67.16 - 67.64 Nm (2.6441 - 2.6630 inch)





3. Measure clearance "C" between reverse brake cam and striking lever while shifting to reverse position.

Clearance "C": 0.05 - 0.125 Nm (0.0020 - 0.0049 inch)

If "H" or "C" is not within specification, replace the following parts as a set.
- Striking lever assembly
- Striking interlock assembly (This includes reverse brake cam.)
- Control bracket assembly

CASE COMPONENTS
REMOVAL AND INSTALLATION
Input Shaft Oil Seal





1. Drive out input shaft oil seal.





2. Install input shaft oil seal.
- Apply multi-purpose grease to seal lip of oil seal before installing.

Input Shaft Rear Bearing





1. Remove welch plug from transmission case.





2. Remove input shaft rear bearing by tapping it from welch plug hole.





3. Install welch plug.
- Apply recommended sealant to mating surface of transmission case.





4. Install input shaft rear bearing.

Mainshaft Front Bearing And Oil Channel





1. Remove mainshaft front bearing retainer.





2. Remove mainshaft front bearing.
3. Remove oil channel.





4. Install oil channel.
- Ensure that the oil groove faces the oil pocket.





5. Install mainshaft front bearing.
6. Install mainshaft front bearing retainer.
- Apply locking sealant to thread of screw before installation.

ADJUSTMENT
DIFFERENTIAL SIDE BEARING PRELOAD
If any of the following parts are replaced, adjust differential side bearing preload.
- Differential case
- Differential side bearing
- Clutch housing
- Transmission case





1. Remove differential side bearing outer race (transmission case side) and shim.





2. Install differential side bearing outer race without shim.
3. Install final drive assembly on clutch housing.
4. Install transmission case on clutch housing.
- Tighten transmission case fixing bolts to the specified torque.





5. Set dial indicator on front end of differential case.
6. Insert Tool all the way into differential side gear.
7. Move Tool up and down and measure dial indicator deflection.
8. Select shim considering bearing preload.
- Suitable shim thickness = dial indicator deflection + specified bearing preload

Differential side bearing adjusting shims: Refer to image.
Bearing preload: 0.25 - 0.30 Nm (0.0098 - 0.0118 inch)

9. Install selected shim and differential side bearing outer race on transmission case.
10. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
- Tighten transmission case fixing bolts to the specified torque.





c. Measure turning torque of final drive assembly.

Turning torque of final drive assembly (New bearing): 2.9 - 6.9 Nm (30 - 70 kg.cm, 26 - 61 inch lbs.)

- When old bearing is reused, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.
- Changes in turning torque of final drive assembly per revolution should be within 1.0 Nm (10 kg.cm, 8.7 inch lbs.) without binding.

ASSEMBLY





1. Install striking rod, lever and interlock.
- Tape edges of striking rod to avoid damaging oil seal lip during installation. When taped edges of striking rod are past the oil seal, remove tape.





2. Install reverse check sleeve assembly.
3. Install check balls, reverse check spring and reverse check plug.





4. Check reverse turning torque (at striking rod).

Reverse check turning torque (at striking rod): 4.9 - 7.4 Nm (50 - 75 kg.cm, 43 - 65 inch lbs.)

- If not within specification, select another check plug having a different length and reinstall it.





Reverse check plugs: Refer to image.

5. Install selected reverse check plug.
- Apply locking sealant to thread of plug before installing it.





6. Install check ball plug, shift check ball and shift check spring.
7. Install oil pocket.





8. Install gear components onto clutch housing.
a. Install final drive assembly.





b. Install input shaft assembly with bearing retainer, mainshaft assembly and reverse idler gear.
- Be careful not to damage oil seal lip with splines of input shaft.
- Be careful not to damage oil channel when inserting mainshaft into clutch housing.





c. Install input shaft front bearing retainer.





9. Apply grease to shifter caps and install to control bracket. Install control bracket with 1st & 2nd shift fork.





- When installing control bracket on clutch housing, ensure bracket is correctly seated.

10. Install 3rd & 4th and 5th shift forks.





11. Insert fork shaft.
- Apply multi-purpose grease to support spring before installing.

12. Install reverse idler spacer.





13. Apply recommended sealant to mating surface of clutch housing.





14. Install transmission case on clutch housing.





15. Install mainshaft front bearing snap ring.





16. Tap mainshaft with a soft hammer to ensure mainshaft is properly seated.





17. Check mainshaft bearing end play.

Mainshaft bearing end play: 0 - 0.1 Nm (0 - 0.004 inch)

- If not within specification, select another case cover having a different thickness.





Available case covers: Refer to image.





18. Install O-ring and case cover on transmission case.
- Apply recommended sealant to mating surface of transmission case.