Removal and Installation

DISASSEMBLY
1. Remove back-up light switch
Torque: 44 N.m (32 ft. lbs.).
2. Remove clutch housing from transmission case. Remove the nine bolts and clutch housing from the transmission case.
Torque: 36 N.m (27 ft. lbs.).
3. Remove control shift lever retainer, as follows:
a. Remove the four bolts.
Torque: 18 N.m (13 ft. lbs.).
b. Remove the oil deflector.
c. Remove two restrict pins
Torque: 37 N.m (27 ft. lbs.).
4. Remove transfer adaptor, as follows:
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.
5. Remove front bearing retainer, as follows:





a. Remove the eight 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
6. Remove bearing snap ring. Using a snap ring expander, remove the two snap rings.
7. Separate intermediate plate from transmission case, as follows:





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

INSTALLATION NOTE: Align the each bearing outer race, each fork shaft end and reverse idler gear shaft end with the case installation holes.
FIPG: THREE BOND 1281 or equivalent.

8. Remove magnet from intermediate plate.
9. Mount intermediate plate in vise, as follows:
a. Use the two 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.





b. Mount the intermediate plate in a vise.
10. Remove straight screw plug, locking ball and spring, as follows:
a. Using a hexagon wrench, remove the four plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 19 N.m (14 ft. lbs.).





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





13. Remove snap ring. Using two screwdrivers and a hammer, tap out the four snap rings from each shift fork shaft.
14. Remove shift fork shaft No.2 and shift fork NO.2, as follows:





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





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.
16. Remove shift fork shaft No.3 and shift fork NO.3, as follows:





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 he sleeve No.3.
c. Using a magnetic finger, remove the interlock pin from the intermediate plate.
17. Remove shift fork shaft No.4, as follows:





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.

c. Using a magnetic finger, remove the spring from the reverse shift fork.
18. Remove reverse shift fork and arm, as follows:





a. Remove the reverse shift fork and arm.

INSTALLATION NOTE: 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.
19. Remove reverse shift arm bracket. Remove the two bolts and reverse shift arm bracket.
Torque: 18 N.m (13 ft. lbs.).
20. Remove output shaft rear bearing, as follows:
a. Using two screwdrivers and a hammer, tap out the snap ring.








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





b. Using Special Service Tool (SST) 09950-40010 or equivalent, remove the rear bearing.





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

21. Remove spacer.





22. 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).
23. Remove gear spline piece No.5, synchronizer ring, needle roller bearing and counter 5th gear with hub sleeve No.3, as follows:








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

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





b. Using SST 09950-50010 or equivalent, remove the gear spline piece No.5.

c. Remove the counter 5th gear with the hub sleeve No.3.

INSTALLATION NOTE:





^ Using SST 09316-60011 (09316-00011) or equivalents, 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 1.4-2.3 kg (3-5 lbs.) hammer or equivalent.

24. Remove thrust washer and ball from counter gear.
25. Remove rear bearing retainer. Remove the four bolts and rear bearing retainer.

INSTALLATION NOTE: Align the rear bearing retainer to the reverse idler gear shaft groove.
Torque: 18 N.m (13 ft. lbs.).





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

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

27. Remove output shaft center bearing snap ring. Using a snap ring expander, remove the snap ring.
28. Remove output shaft and counter gear from intermediate plate, as follows:





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.





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

ASSEMBLY
Assembly is in the reverse order of disassembly.

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