Components Disassembly and Assembly

Shift Control Components: Disassembly and Assembly

Disassembly

Shift Control Components

1) Remove rear extension (or OD gear case) and transmission case. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
2) Install Tool to adapter plate, and then position in a vise.











CAUTION:
Do not directly secure mating surface of adapter plate in a vise.

3) Remove baffle plate bolts, and then remove baffle plate from adapter plate.





4) Remove check ball plugs, check ball springs and check balls from adapter plate.





5) Remove 3rd-4th control lever bolts, and then remove 3rd-4th control lever and shifter cap from adapter plate.





6) Remove retaining pin using suitable tool, and then remove 3rd - 4th fork rod bracket and 3rd-4th fork rod from adapter plate.





7) Remove check balls and interlock pin from adapter plate.





8) Remove retaining pin using a suitable tool, and then remove 3rd-4th shift fork and 3rd-4th fork rod (reversal side) from adapter plate.





9) Remove retaining pin using a suitable tool, and then remove 1st-2nd shift fork and 1st-2nd fork rod from adapter plate.





10) Remove interlock plunger and interlock pin from adapter plate.





11) Remove retaining pin using suitable tool, and then remove reverse shift fork and reverse fork rod from adapter plate.





12) Remove check balls from adapter plate.





13) Remove retaining pin using suitable tool, and then remove 5th-6th fork rod bracket and 5th-6th fork rod from adapter plate.





14) Remove 5th-6th control lever bolts, and then remove 5th-6th control lever from adapter plate.





15) Remove retaining pin using suitable tool, and then remove 5th-6th shift fork and 5th-6th fork rod (reversal side) from adapter plate.





16) Remove retaining pin using suitable tool, and then remove stopper ring from striking rod assembly.





17) Remove striking rod assembly from adapter plate.






Assembly

Shift Control Components

1) Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft assembly. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
2) Install striking rod assembly according to the following.
a) Install striking rod assembly to adapter plate.





b) Install stopper ring to striking rod assembly.





c) Install retaining pin onto stopper ring using suitable tool.

CAUTION:
Do not reuse retaining pin.

3) Install 5th-6th fork rod (reversal side) according to the following.
a) Install 5th-6th shift fork to 5th-6th coupling sleeve.





b) Install 5th-6th fork rod (reversal side) to 5th-6th shift fork.
c) Install retaining pin onto 5th-6th shift fork using suitable tool.

CAUTION:
Do not reuse retaining pin.

4) Install 5th-6th control lever to adapter plate, and then tighten bolts to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.






CAUTION:
Install 5th-6th control lever with projection side upward.

5) Install 5th-6th fork rod according to the following.
a) Install 5th-6th fork bracket and 5th-6th fork rod to adapter plate.





b) Install retaining pin onto 5th-6th fork bracket using suitable tool.

CAUTION:
Do not reuse retaining pin.

6) Install check balls to adapter plate.






CAUTION:
Apply gear oil to check balls.

7) Install reverse fork rod according to the following.
a) Install reverse shift fork to reverse coupling sleeve.





b) Install reverse fork rod to reverse shift fork.
c) Install retaining pin onto reverse shift fork using suitable tool.

CAUTION:
Do not reuse retaining pin.

8) Install interlock pin and interlock plunger to adapter plate.






CAUTION:
Apply gear oil to interlock pin and interlock plunger.

9) Install 1st-2nd fork rod according to the following.
a) Install 1st-2nd shift fork to 1st-2nd coupling sleeve.





b) Install 1st-2nd fork rod to 1st-2nd shift fork.
c) Install retaining pin onto 1st-2nd shift fork using suitable tool.

CAUTION:
Do not reuse retaining pin.

10) Install interlock pin and check balls to adapter plate.






CAUTION:
Apply gear oil to interlock pin and check balls.

11) Install 3rd-4th fork rod (reversal side) according to the following.
a) Install 3rd-4th shift fork to 3rd-4th coupling sleeve.





b) Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
c) Install retaining pin onto 3rd-4th shift fork using suitable tool.

CAUTION:
Do not reuse retaining pin.

12) Install 3rd-4th fork rod according to the following.
a) Install 3rd-4th fork rod to adapter plate.





b) Install 3rd-4th fork rod bracket to 3rd-4th fork rod.
c) Install retaining pin onto 3rd-4th fork rod bracket using suitable tool.

CAUTION:
Do not reuse retaining pin.

13) Install 3rd-4th control lever according to the following.
a) Install shifter cap to 3rd-4th control lever.





b) Install 3rd-4th control lever to adapter plate, and then tighten bolts to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

CAUTION:
Be careful with the orientation 3rd-4th control lever.

14) Install check ball plug according to the following.
a) Install check balls, check ball springs to adapter plate.






CAUTION:
Apply gear oil to check ball.

b) Apply recommended sealant to threads of check ball plugs, and tighten check ball plugs to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
- Use Genuine Silicone RTV or the equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.
15) Install baffle plate to adapter plate, and then tighten bolt to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.