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.
Tool number: ST30720000 (J-25405)
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.
Tool number: ST33200000 (J-26082)
5. Install bearing retainer.
CAUTION: Install with the punched surface facing up.
6. Install differential side bearing outer race.
Tool number: ST30720000 (J-25405)
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 interlock 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.
a. Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork.
CAUTION: Do not drop the 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.
Bracket bolts: 11.8 - 15.6 Nm (1.2 - 1.5 kg-m, 9 - 11 ft. lbs.)
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 "Available Adjusting Shims".
23. Install selected differential side bearing adjusting shim and differential side bearing outer race. For selection adjusting shim, refer to "DIFFERENTIAL SIDE BEARING PRELOAD".
24. Install baffle plate and oil gutter.
25. Install transaxle case:
a. Install selected mainshaft rear bearing adjusting shim into transaxle case.
^ For selection of adjusting shims, refer to "Available Adjusting Shims".
b. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
CAUTION: Do not reuse the snap ring.
c. Apply Genuine Silicone RTV or equivalent to mating surfaces of transaxle case and clutch housing. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
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, lift up mainshaft assembly from the control assembly mounting hole.
f. Securely install snap ring onto mainshaft rear bearing.
g. Tighten the 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. Apply gear oil to the O-ring and install it to the control assembly. Then install control assembly to transaxle case. Tighten bolts to the specified torque. Refer to "SHIFT CONTROL COMPONENTS".
CAUTION: Do not reuse O-ring.
i. Install shift check and a new stopper bolt.
CAUTION: Shift check and stopper bolt are not reusable.
26. Using Tool, install a new bore plug as shown.
CAUTION: Bore plugs are not reusable.
Tool number: ST33061000 (J-8107-2)
27. Using Tool, install a Welch plug as shown.
Tool number: ST33052000 ( - )
28. 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.
29. Apply Genuine Silicone RTV or equivalent to threads of Park/Neutral position switch and Back-up lamp switch, then install them into transaxle case. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
30. Install gaskets onto drain plug and filler plug, then install them into transaxle case.
CAUTION:
^ Gaskets are not reusable. Never reuse them.
^ After oil is filled, tighten filler plug to specified torque. Refer to "CASE AND HOUSING COMPONENTS".