Assembly
ASSEMBLY
1. Install a new input shaft oil seal from the clutch housing end of the side, to the depth of 1.8 - 2.8 mm (0.071 - 0.110 inch)using Tool as shown.
CAUTION: Do not reuse the oil seals.
2. Install a new differential oil seal using Tool (drift) as shown.
CAUTION: Do not reuse the oil seals.
3. Install the oil channel on the mainshaft side as shown.
CAUTION: Position the oil channel with the orientation as shown, for installation.
4. Install the mainshaft front bearing using Tool (drift) as shown.
CAUTION: Position the mainshaft front bearing with the orientation as shown, for installation
5. Install the mainshaft front bearing retainer.
CAUTION: Install the bearing retainer with the punched surface facing up.
Retainer bolt : 6.27 - 8.33 Nm (0.64 - 0.84 kg-m, 56- 73 inch lbs.)
6. Install the differential side bearing outer race using Tool as shown.
7. Install the final drive assembly into the clutch housing.
8. Install the input shaft assembly, mainshaft assembly, and reverse idler gear assembly into the clutch housing.
CAUTION: Do not damage the input shaft oil seal.
9. Install the 1st-2nd fork rod bracket onto the 1st-2nd fork rod, and then install a new retaining pin as shown.
CAUTION: Do not reuse the retaining pins.
10. Install the 1st-2nd fork rod and the 1st-2nd shift fork, and then install a new retaining pin.
CAUTION: Do not reuse the retaining pins.
11. Install the shift check sleeve.
12. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with the interlock pin.
13. Install the new stopper rings onto the 3rd-4th shift fork.
CAUTION: Do not reuse the stopper rings.
14. Install a new retaining pin onto the 3rd-4th bracket.
CAUTION: Do not reuse the retaining pins.
15. Install the 2 check balls.
16. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
17. Install new stopper rings onto the 5th-6th bracket with interlock pin.
CAUTION: Do not reuse the stopper rings.
18. Install a new retaining pin onto the 5th-6th shift fork.
CAUTION: Do not reuse the retaining pins.
19. Install the two check balls.
20. Install the 5th-6th check ball, 5th-6th shift check sleeve, 5th-6th check spring, and the 5th-6th check plug.
CAUTION:
^ Do not reuse the check plug.
^ Do not drop the check ball.
21. Install the reverse bracket fork rod and reverse lever bracket.
22. Install a new retaining pin onto the reverse bracket.
CAUTION: Do not reuse the retaining pins.
23. Install the reverse shift fork and reverse fork rod.
24. Install the reverse lever assembly using the following steps:
a. Install the shifter cap onto the reverse lever assembly cam, and then install them onto the reverse shift fork.
CAUTION: Do not drop the shifter cap.
b. While lifting the reverse shift fork, align the cam with the reverse bracket.
c. Tighten the bracket bolts to specification, and install the reverse lever assembly.
Bracket bolts : 11.8 - 15.6 Nm (1.2 - 1.5 kg-m, 9 - 11 ft. lbs.)
25. Install the check ball, reverse shift check sleeve, reverse check spring, and the reverse check ball plug.
CAUTION:
^ Do not reuse the check plug.
^ Do not drop the check ball.
26. Install the magnet onto the clutch housing.
27. Install the selected input shaft adjusting shim onto the input shaft.
^ For selection of adjusting shims, refer to "INPUT SHAFT END PLAY".
28. Install the selected differential side bearing adjusting shim and differential side bearing outer race.
^ For selection of adjusting shims, refer to "DIFFERENTIAL SIDE BEARING PRELOAD".
29. Install the baffle plate and oil gutter.
30. Install the transaxle case using the following steps:
a. Install the selected mainshaft rear bearing adjusting shim into the transaxle case.
^ For selection of adjusting shims, refer to "MAINSHAFT END PLAY".
b. Temporarily install the snap ring of the mainshaft rear bearing into the transaxle case.
CAUTION: Do not reuse the snap ring.
c. Apply sealant to the mating surfaces of the transaxle case and clutch housing as shown. Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
CAUTION: Remove any old sealant adhering to the mounting surfaces. Also remove any moisture, oil, or foreign material adhering to the sealant application and mounting surfaces.
d. Using a snap ring of the mainshaft rear bearing temporarily, install the transaxle case over the clutch housing as shown.
e. Through the bore plug mounting hole, with the snap ring stretched, lift up the mainshaft assembly from the control assembly mounting hole.
f. Securely install the snap ring onto the mainshaft rear bearing as shown.
g. Tighten the "A" bolts (gold) and new "B" bolts (black) to specification.
"A" Bolt : 50.0 - 53.9 Nm (5.1 - 5.4 kg-m, 37 - 39 ft. lbs.)
"B" Bolt : 63.0 - 66.9 Nm (6.5 - 6.8 kg-m, 47 - 49 ft. lbs.)
CAUTION: Always replace the "B" bolts as they are self-sealing bolts.
h. Apply gear oil to O-ring and install it to the control assembly. Then install the control assembly to the transaxle case. Tighten the bolts to the specified torque. Refer to "SHIFT CONTROL COMPONENTS"
CAUTION: Do not reuse the O-ring.
i. Install a new shift check and a new stopper bolt.
CAUTION: Do not reuse the shift check and stopper bolt.
31. Install a new bore plug using Tool (drift) as shown.
CAUTION: Do not reuse the bore plugs.
32. Install the new Welch plug using Tool (drift).
CAUTION: Do not reuse the Welch plug.
33. Install the 2 check balls, 2 check springs, and the 2 new check plugs.
CAUTION: Do not reuse the check plugs.
34. Apply sealant to the threads of the park/neutral position switch and back-up lamp switch. Then install them into the transaxle case. Refer to "CASE AND HOUSING COMPONENTS". Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS"
35. Install a new gasket onto the drain plug and then install it into the transaxle case.
CAUTION: Do not reuse the gasket.
36. Fill the transaxle with the specified fluid. Refer to "M/T OIL".