Assembly

1. Put main shaft input shaft assembly (1) into lower case (2), apply oil to component parts and check for proper engagement (smooth rotation) with counter shaft.
2. After cleaning mating surfaces of both cases, coat mating surface of upper case (3) with sealant "A", evenly and put it over lower case. At this time, all gears and forks should be set to neutral position.





3. Place bolts at their positions and check to make sure that their height from case surface is the same before tightening them. Also, check clamp position and torque them to (a) 23 Nm (17.0 ft. lbs.)





4. Apply sealant "A" to mating surface of input shaft bearing retainer (1) and its bolts (2), then install them.
Tightening Torque (b) 23 Nm (17.0 ft. lbs.)





5. Install clutch housing (1) and torque its bolts (2) to (c) 50 Nm (36.5 ft. lbs.)
6. Install release bearing.





7. Clean mating surfaces of both cases, coat mating surface of extension case with sealant "A" evenly and mate it with transmission itself.





8. Install extension case bolts and torque them to (d) 23 Nm (17.0 ft. lbs.)





9. Install back up light switch (1).
Tightening Torque (e) 20 Nm (14.5 ft. lbs.)
10. Install gear shift lever case temporarily to confirm switch function by checking that the back up light switch should conduct when gear shift control lever (2) is at reverse position.
11. After confirming switch function, remove gear shift lever.





12. Clamp wiring harness and breather hose as they are.