Part 1 of 2

1. INSERT NO. 1 AND NO. 2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
CAUTION: Install the key springs positioned so that their end gaps are not in line.

2. INSTALL THIRD GEAR AND NO. 2 CLUTCH HUB ON OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.

3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play, and install it on the shaft.

4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)

5. INSTALL SECOND GEAR AND NO. 1 CLUTCH HUB
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.

(d) Using a press, install the 2nd gear and No. 1 clutch hub.

6. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY
(a) Install the locking bail in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race.

(d) Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball.

7. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft with the outer race snap ring groove toward the rear.
NOTE: Hold the 1st gear inner race to prevent it from falling.
SST 09506-35010

8. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st and 2nd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)

9. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE
(a) Before installing the output shaft, use SST to remove the counter gear center bearing outer race.
SST 09608-35014 (09608-06020, 09608-06090)
NOTE: Install the outer race after installing the counter gear.

(b) Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.

10. INSTALL INPUT SHAFT AND COUNTER GEAR
(a) Install the input shaft and counter gear together.

(b) Using SST, install the counter gear center bearing outer race.
SST 09316-60010 (09316-00010)
NOTE: Be careful not to damage the bearing rollers.

11. INSTALL BEARING RETAINER
(a) Using snap ring pliers, install the bearing snap ring.
NOTE: Be sure the snap ring is flush with the intermediate plate surface.
(b) Using a torx socket wrench, tighten the screws.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)

12. INSTALL REVERSE GEAR
Using SST, install the reverse gear.
SST 09312-20011

13. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.

14. (5-Speed)
INSTALL FIFTH GEAR AND OUTPUT SHAFT REAR BEARING
Using SST, install the 5th gear and rear bearing.
SST 09312-20011

15. (5-Speed)
INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.

16. (5-Speed)
INSERT NO. 3 CLUTCH HUB INTO HUB SLEEVE
(a) Install No. 3 clutch hub and the shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
CAUTION: Install the key springs positioned so that their end gaps are not in line.

17. (5-Speed)
INSTALL NO. 3 CLUTCH HUB
Using SST, drive in No. 3 clutch hub.
SST 09316-60010 (09316-00010, 09316-00070)
NOTE: When installing the clutch hub, support the countershaft in front with a 3-5 lb hammer or equivalent.

18. (5-Speed)
INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.

19. (5-Speed)
INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING AND COUNTER FIFTH GEAR
(a) Install the bearing spacer.
(b) Apply gear oil to the needle roller bearings.
(c) Assemble the counter 5th gear, synchronizer ring and needle roller bearings.

(d) Install the 5th gear assembly with the synchronizer. ring slots aligned with the shifting keys.

20. (5-Speed)
INSTALL SPACER AND BEARING
(a) Install the spacer.
(b) Install the bearing with the ball shield toward the rear.
(c) Using a hammer and socket wrench, drive in the bearing.
NOTE: When driving in the bearing, Support the counter- shaft in front with a 3-5 lb hammer or equivalent.

21. (5-Speed)
INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.

22. (2WD)
INSTALL SPEEDOMETER DRIVE GEAR
(a) Put a clip on the output shaft and install the drive gear clip into the slot.
(b) Slide the drive gear with clip and fit the clip into the holes.

23.-i (4-Speed)
INSTALL SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Install the reverse shift arm and No. 3 shift fork shaft.
(1) Put the reverse shift arm into the pivot of the bearing retainer and install No. 3 shift fork shaft to the intermediate plate.

(2) Apply MP grease to No. 3 interlock pin and install the pin into the intermediate plate hole.

(b) Install the reverse idler gear and shaft.
Align the reverse idler gear groove to the reverse shift arm shoe and install the reverse idler gear shaft to the intermediate plate.

(c) Install No. 2 shift fork and fork shaft.
(1) Apply MP grease to No. 2 interlock pin and install the pin into the shaft hole.

(2) Place No. 2 shift fork into the groove of No. 2 hub sleeve.
(3) Install No. 2 fork shaft to the shift fork through the intermediate plate.

(d) Install the snap ring of No. 2 fork shaft.

(e) Apply MP grease to No. 1 interlock pin and install the pin into the intermediate plate.

(f) Install No. 1 shift fork and fork shaft.
(1) Install No. 1 shift fork into the groove of No. 1 hub sleeve.
(2) Insert No. 1 fork shaft to the shift fork through the intermediate plate.

(g) Install the snap ring of No. 1 fork shaft.

(h) Install the shift fork set bolts with lock washers.
Torque: 125 kg-cm (9 ft-lb, 12 N-m)

(i) Using pliers, stake the bolts with lock washers.

23.-2 (5-Speed)
INSTALL SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Install the reverse idler gear and shaft.
(b) Install No. 3 shift fork, No. 3 fork shaft and reverse shift arm.
(1) Coat the pin with MP grease and insert it into the reverse shift head hole.

(2) Insert No. 3 shift fork shaft through No. 3 shift fork and the reverse shift arm.
(3) Align No. 3 shift fork with the No. 3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove. Install No. 3 shift fork shaft to the intermediate plate,

(c) Install No. 4 shift fork shaft.
(1) Push the pin, which was inserted into the reverse shift arm hole, into the groove of No. 3 shift fork shaft.

(2) Install No. 4 shift fork shaft to the intermediate plate over the reverse shift arm.

(d) Using a pin punch and hammer, drive in the slotted spring pin until it is flush with the fork.

(e) Apply MP grease to No. 3 interlock pin and install the pin into the intermediate plate hole.

(f) Install No. 2 shift fork and fork shaft.
(1) Apply MP grease to No. 2 interlock pin and install the pin into the shaft hole.

(2) Place No. 2 shift fork into the groove of No. 2 hub sleeve.
(3) Install No. 2 fork shaft to the shift fork through the intermediate plate.

(g) Install the snap ring of No. 2 fork shaft.

(h) Apply MP grease to No. 1 interlock pin and install the pin into the intermediate plate.

(i) Install No. 1 shift fork and fork shaft.
(1) Install No. 1 shift fork into the groove of No. 1 hub sleeve.
(2) Insert No. 1 fork shaft to the shift fork through the intermediate plate.

(j) Install the snap ring of No. 1 fork shaft.

(k) Install the shift fork set bolts with lock washers.
Torque: 125 kg-cm (9 ft-lb, 12 N-m)

(l) Using pliers, stake the bolts with lock washers.