Assembly
ASSEMBLY
1. Using a drift, install a new input shaft oil seal from the clutch housing end of side to the depth of 1.8 - 2.8 mm (0.071 - 0.110 inch).
CAUTION: Oil seals are not reusable.
2. Using a drift, install a new differential oil seal.
CAUTION: Oil seals are not reusable.
3. Install oil channel on mainshaft side as shown.
CAUTION: Use the correct orientation for installation as shown.
4. Using a drift, install mainshaft front bearing.
CAUTION: Use the correct orientation for installation as shown.
5. Install bearing retainer.
CAUTION: Install with the punched surface facing up.
6. Install differential side bearing outer race.
7. Install final drive assembly into clutch housing.
8. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.
CAUTION: Be sure not to damage input shaft oil seal.
9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then install retaining pin.
CAUTION: Retaining pins are not reusable. Never reuse them.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install retaining pin.
CAUTION: Retaining pins are not reusable. Never reuse them.
11. Install shift check sleeve.
12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with inter lock pin.
13. Install stopper ring onto 3rd-4th shift fork.
CAUTION: Stopper rings are not reusable. Never reuse them.
14. Install retaining pin onto 3rd-4th bracket.
CAUTION: Retaining pins are not reusable. Never reuse them.
15. Install 2 check balls.
16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork rod.
17. Install stopper ring onto 5th-reverse bracket.
CAUTION: Stopper rings are not reusable. Never reuse them.
18. Install retaining pin onto 5th shift fork.
CAUTION: Retaining pins are not reusable. Never reuse them.
19. Install reverse shift fork and reverse fork rod.
20. Install reverse lever assembly following procedures below.
a. Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork.
CAUTION: Do not drop shifter cap.
b. While lifting reverse shift fork, align cam with 5th-reverse bracket.
c. Tighten mounting bolts to specified torque, and then install reverse lever assembly.
21. Install the magnet onto clutch housing.
22. Install the selected input shaft adjusting shim onto the input shaft.
^ For selection of adjusting shims, refer to Specifications.
23. Install baffle plate and oil gutter.
24. Install transaxle case using the following procedure:
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
^ For selection of adjusting shims, refer to Specifications.
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION: Do not reuse the snap ring.
c. Apply Anaerobic Liquid Gasket or equivalent to mating surfaces of transaxle case and clutch housing.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
d. With snap ring of mainshaft rear bearing temporarily installed, place transaxle case over clutch housing.
e. Through bore plug mounting hole, with snap ring stretched, and lift up mainshaft assembly from the control assembly mounting hole.
f. Securely install snap ring onto mainshaft rear bearing.
g. Tighten the mounting bolts "A" and the new bolts "B".
Bolt "A" : 50.0 - 53.9 Nm (5.1 - 5.4 kg-m, 37 - 39 ft. lbs.)
Bolt "B" : 63.0 - 66.9 Nm (6.5 - 6.8 kg-m, 47 - 49 ft. lbs.)
CAUTION: Always replace bolts "B" because they are self-sealing bolts.
h. Install control assembly.
CAUTION: Do not reuse the O-ring.
i. Install shift check and a new stopper bolt.
CAUTION: Shift check and stopper bolt are not reusable.
25. Using a drift, install a new bore plug as shown.
CAUTION: Bore plugs are not reusable.
26. Install a Welch plug using a drift.
27. Install 1 shift check sleeve, 3 check balls, 3 check springs, and 3 check ball plugs.
CAUTION: Check ball plugs are not reusable. Never reuse them.
28. Apply Anaerobic Liquid Gasket or equivalent to threads of neutral switch and reverse lamp switch. Then install them into transaxle case.
29. Install gaskets onto drain plug and filler plug, and then install them into transaxle case.
CAUTION:
^ Gaskets are not reusable. Never reuse them.
^ After oil is filled, tighten filler plug to specified torque.