Assembly
ASSEMBLY
1. Install a new input shaft oil seal from the clutch housing end, to a depth of 1.8 - 2.8 mm (0.071 - 0.110 inch) using Tool as shown.
CAUTION: Oil seals are not reusable.
2. Install a new differential oil seal using Tool as shown.
CAUTION: Oil seals are not reusable.
3. Install oil channel on mainshaft side.
CAUTION: Position oil channel with specified orientation for installation as shown.
4. Install mainshaft front bearing using Tool as shown.
CAUTION: Install with orientation as shown.
5. Install bearing retainer for mainshaft front bearing.
Bearing retainer bolt: 6.27 - 8.33 Nm (0.64 - 0.84 kgf-cm, 56- 73 inch lbs.)
CAUTION: Install with the punched surface facing up.
6. Install differential side bearing outer race using Tool as shown.
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 a new retaining pin.
CAUTION: Retaining pins are not reusable.
10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install a new retaining pin.
CAUTION: Retaining pins are not reusable.
11. Install shift check sleeve.
12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with interlock pin.
13. Install a new stopper ring onto 3rd-4th shift fork.
CAUTION: Stopper rings are not reusable.
14. Install a new retaining pin onto 3rd-4th bracket.
CAUTION: Retaining pins are not reusable.
15. Install 2 check balls.
16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork rod.
17. Install a new stopper ring onto 5th-reverse bracket.
CAUTION: Stopper rings are not reusable.
18. Install a new retaining pin onto 5th shift fork.
CAUTION: Retaining pins are not reusable.
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 fork rod bracket.
c. Install the reverse lever assembly and tighten the reverse lever assembly bolts to specification.
Reverse lever assembly bolts: 11.8 - 15.6 Nm (1.2 - 1.5 kgf-cm, 9 - 11 ft. lbs.)
21. Install the magnet onto clutch housing.
22. Install selected input shaft adjusting shim onto input shaft.
^ For selection of adjusting shims, refer to "INPUT SHAFT END PLAY".
23. Install baffle plate and oil gutter.
24. Install transaxle case following procedures below.
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
^ For selection of adjusting shims, refer to "MAINSHAFT END PLAY".
b. Temporarily install a new snap ring for the mainshaft rear bearing into transaxle case.
CAUTION: Do not reuse the snap ring.
c. Apply sealant to mating surfaces of transaxle case and clutch housing. Use Genuine Anaerobic Liquid Gasket or equivalent.
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 as shown.
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 as shown.
g. Tighten mounting bolts "A" and "B" to specification as shown.
Bolt A : 50.0 - 53.9 Nm (5.1 - 5.4 kgf-cm, 37 - 39 ft. lbs.)
Bolt B : 63.0 - 66.9 Nm (6.5 - 6.8 kgf-cm, 47 - 49 ft. lbs.)
CAUTION: Always replace bolts "B" as they are self-sealing bolts.
h. Install control assembly.
CAUTION: Do not reuse the O-ring.
i. Install a new shift check and a new stopper bolt.
CAUTION: Shift check and stopper bolt are not reusable.
25. Install a new bore plug using Tool as shown.
CAUTION: Bore plugs are not reusable.
26. Install a new Welch plug using Tool as shown.
CAUTION: Do not reuse the Welch plug.
27. Install 1 shift check sleeve, 3 check balls, 3 check springs, and 3 new check ball plugs as shown.
CAUTION: Check ball plugs are not reusable.
28. Apply sealant to threads of PNP switch and back-up lamp switch, then install them into transaxle case. Use Genuine Anaerobic Liquid Gasket or equivalent.
29. Install new gaskets onto drain plug and filler plug, and then install them into transaxle case.
CAUTION:
^ Gaskets are not reusable.
^ After oil is filled, tighten filler plug to specified torque.