Removal and Installation

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY
1. Remove back-up light switch.
Torque: 44 N.m (32 ft. lbs.)
2. Remove clutch housing.
Remove the 9 bolts and clutch housing.
Torque: 36 N.m (27 ft. lbs.)
3. Remove control shift lever retainer.
Remove the 4 bolts, retainer and oil deflector.
Torque: 18 N.m (13 ft. lbs.)
4. Remove 2 restrict pins.
Torque: 37 N.m (27 ft. lbs.)





5. Remove transfer adaptor.
a. Remove the shift lever housing set bolt.
Torque: 38 N.m (28 ft. lbs.)
b. Remove the 10 bolts. Torque: 37 N.m (27 ft. lbs.)
c. Using a plastic hammer, tap the transfer adaptor, remove the shift lever housing and shift and select lever.

FIPG: THREE BOND 1281 or equivalent.





6. Remove front bearing retainer.
a. Remove the 8 bolts.

Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.

Torque: 17 N.m (12 ft. lbs.)
b. Using a plastic hammer, tap the front bearing retainer.

FIPG: THREE BOND 1281 or equivalent.

7. Remove bearing snap ring.
Using a snap ring expander, remove the 2 snap rings.





8. Separate intermediate plate from transmission case.
a. Using a brass bar and hammer, carefully tap the transmission case.
b. Remove the transmission case from the intermediate plate.

INSTALLATION HINT: Align the each bearing outer race, each fork shaft end and reverse idler gear shaft end with the case installation holes.

FIPG: Part No. 08826 00090, THREE BOND 1281 or equivalent.

9. Remove magnet from intermediate plate.





10. Mount intermediate plate in vise.
a. Use the 2 clutch housing bolts, plate washers and suitable nuts, as shown.

INSTALLATION NOTICE: increase or decrease plate washers so that the bolt tip does not protrude from the nut.

Mount the intermediate plate in a vise.





11. Remove straight screw plug, locking ball and spring.
a. Using a hexagon wrench, remove the 4 plugs.

Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.

Torque: 19 N.m (14 ft. lbs.)
b. Using a magnetic finger, remove the 3 springs and balls.
12. Remove shift fork set bolt Remove the 2 bolts from the shift forks No.1 and No.2.
Torque: 20 N.m (14 ft. lbs.)
13. Remove slotted spring pin.
Using a pin punch and hammer, drive out the pin from the shift fork No.3.





14. Remove snap ring.
Using 2 screwdrivers and a hammer, tap out the 4 snap rings from each shift fork shaft.





15. Remove shift fork shaft No.2 and shift fork No.2.
a. Pull out the shift fork shaft No.2 from the shift forks No.1, No.2 and intermediate plate.
b. Remove the shift fork No.2 from the groove of hub sleeve No.2.
Using a magnetic finger, remove the interlock pin from the intermediate plate.





16. Remove shift fork shaft No.1 and shift fork No.1.
a. Pull out the shift fork shaft No.1 with the straight pin from the shift fork No.1 and intermediate plate.
b. Remove the shift fork No.1 from the groove of reverse gear.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.





17. Remove shift fork shaft No.3 and shift fork No.3.
a. Pull out the shift fork shaft No.3 from the shift fork No.3, reverse shift fork and intermediate plate.
b. Remove the shift fork No.3 from the groove of hub sleeve No.3.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.





18. Remove shift fork shaft No.4.
a. Using a magnetic finger, remove the ball.
b. Pull out the shift fork shaft No.4 from the reverse shift fork and intermediate plate.

REMOVAL NOTICE: Take care of the ball in the reverse shift fork. It will spring out when you pull out the shift fork shaft No.4.

Using a magnetic finger, remove the spring from the reverse shift fork.





19. Remove reverse shift fork and arm.
a. Remove the reverse shift fork and arm.

INSTALLATION HINT: Align the reverse shift arm to the pivot of the reverse shift arm bracket.

b. Using a screwdriver, remove the E-ring.
c. Separate the reverse shift fork and arm.
20. Remove reverse shift arm bracket Remove the 2 bolts and reverse shift arm bracket.
Torque: 18 N.m (13 ft. lbs.)





21. Remove output shaft rear bearing.
a. Using 2 screwdrivers and a hammer, tap out the snap ring.





INSTALLATION HINT: Select a snap ring that will allow minimum axial play.





b. Using Special Service Tool (SST) 09950-0010, remove the rear bearing.





INSTALLATION HINT: Using SST 09316-60011 (09316-00011, 09316-00071) and a hammer, drive in a new bearing.

22. Remove spacer.





23. Inspect counter 5th gear thrust clearance Using a feeler gauge, measure the counter 5th gear thrust clearance.
Standard clearance: 0.10-0.35 mm (0.0039-0.0138 inch)
Maximum clearance: 0.40 mm (0.0157 inch)
24. Remove gear spline piece No.5, synchronizer ring, needle roller bearing and counter 5th gear with hub sleeve No.3.





a. Using 2 screwdrivers and a hammer, tap out the snap ring.





INSTALLATION HINT: Select a snap ring that will allow minimum axial play.





b. Using SST 09950 - 50010, remove the gear spline piece No.5.
c. Remove the counter 5th gear with the hub sleeve No.3.





INSTALLATION HINT:
- Using SST 09316-60011 (09316-00011) and a hammer, drive in the gear spline piece No.5 with the synchronizer ring slots aligned with the shifting keys.
- When installing the gear spline piece No.5, support the counter gear in front with a 3-5 lb hammer or equivalent.

25. Remove thrust washer and ball from counter gear.
26. Remove rear bearing retainer.
Remove the 4 bolts and rear bearing retainer.

INSTALLATION HINT: Align the rear bearing retainer to the reverse idler gear shaft groove.

Torque: 18 N.m (13 ft. lbs.)





27. Remove reverse idler gear and shaft.
Pull out the shaft toward the rear.

INSTALLATION HINT: Align the reverse shift arm to the reverse idler gear shaft.

28. Remove output shaft center bearing snap ring Using a snap ring expander, remove the snap ring.





29. Remove output shaft and counter gear from intermediate plate.
a. Remove the output shaft, counter gear and input shaft as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
b. Remove the input shaft with the needle roller bearing from the output shaft.





30. Remove counter rear bearing from intermediate plate Using SST 09950-60010 (09951-00620), 09950-70010 (09951-07150) and a hammer, remove the counter rear bearing.

REASSEMBLY
Reassembly is in the reverse order of disassembly.

HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly.