Clutch Housing

Clutch Housing





1. Hammer the striking rod oil seal into clutch housing as far as it will go using Tool.

CAUTION: Do not reuse striking rod oil seal.





2. Hammer the differential oil seal into clutch housing with a suitable tool until it becomes flush with clutch housing end face.

CAUTION: Do not reuse differential oil seal.





3. Hammer input shaft oil seal into clutch housing as far as it will go with a suitable tool.

CAUTION: Do not reuse input shaft oil seal.





4. Hammer the dust seal into clutch housing as far as it will go using Tool.

CAUTION: Do not reuse dust seal.





5. Install outer race of differential side bearing using Tool.





6. Install new oil channel (mainshaft).

CAUTION: Pay attention to installation direction of oil channel.





7. Align the notches on mainshaft front bearing and transaxle case. Then, install mainshaft front bearing with a suitable tool.





8. Install mainshaft bearing retainer, and tighten bolts with specified torque.





9. Attach boot, striking rod, and striking lever to clutch housing. And install retaining pin for selector lever using Tool.

CAUTION:
- Before installing striking rod, wrap the end with a vinyl tape or similar product to prevent oil seal from being damaged.
- Do not reuse retaining pin.





10. Hammer the welch plug (striking lever side) with a general purpose drift [OD: 12 mm (0.47 inch)] with a suitable tool.

CAUTION: Do not reuse welch plug.





11. Install selector, selector shaft, and selector shaft pin into clutch housing.





12. Hammer the welch plug (selector shaft side) with a general purpose drift [OD: 12 mm (0.47 inch)] with a suitable tool.

CAUTION: Do not reuse welch plug.





View: Exploded





View: Assembled

13. Install select check leaf spring, return spring, steel ball, reverse gate, selector arm, bushing, and return bearing. Then, tighten two reamer bolts with specified torque.

CAUTION: Use correct reamer bolts for each installation point, because each bolt has a different length.





14. Install oil pocket.





15. Install differential assembly, input shaft assembly, and mainshaft assembly into clutch housing.

CAUTION: Be careful not to damage input shaft oil seal during installation of input shaft assembly.

16. Install 5th & reverse shift fork.





17. Install 1st & 2nd shift fork, bracket, and fork rod using Tool.
18. Install retaining pin for 1st & 2nd bracket.

CAUTION: Do not reuse retaining pin.

19. Install two check balls.





20. Install interlock pin into 5th & reverse fork rod using Tool.
21. Install reverse switch bracket, 5th & reverse bracket, and fork rod using Tool.
22. Install retaining pin for 5th & reverse shift fork and reverse switch bracket using Tool.

CAUTION: Do not reuse retaining pin.

23. Install 5th & reverse bracket stopper ring.

CAUTION: Do not reuse stopper pin.

24. Install check ball and interlock plunger.





25. Install 3rd & 4th shift fork, bracket, and fork rod using Tool.
26. Install 3rd & 4th bracket retaining pin.

CAUTION: Do not reuse retaining pin.





27. Install 3rd & 4th shift fork stopper ring.

CAUTION: Do not reuse stopper ring.

28. Install check ball, check pin, and check spring, and apply Three Bond TB1215, Loctite Part No. 51813 or equivalent onto check plug. Then, tighten it with specified torque.
Tightening torque: Refer to "Shift Control Components", under Major Overhaul.