Manual Transmission

REMOVAL
1. Remove speed sensor driven gear.
Torque: 12 N.m (108 inch lbs.)
2. Remove transfer indicator switch.
Torque: 37 N.m (27 ft. lbs.).
3. Automatic Transmission (A/T):
Remove transfer L4 and neutral position switch.
Torque: 37 N.m (27 ft. lbs.).

INSTALLATION NOTE: Check following items
^ Check to see that the input shaft and output shafts rotate smoothly.
^ Check to see that shifting can be made smoothly to all position.
5. Remove front retainer, as follows:





a. Remove the 7 bolts.
Torque: 12 N.m (108 inch lbs.).

INSTALLATION NOTE: Apply liquid sealer to the bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent

b. Using a plastic hammer, tap the front retainer and remove it.

INSTALLATION NOTE:
^ Remove any Formed In Place Gasket (FIPG) material and be careful not to drop oil on the contacting surfaces of the front retainer.





^ Apply FIPG to the front retainer, as shown.
FIPG: THREE BOND 1281, LOCTITE 242 or equivalent.

6. Remove control retainer, as follows:
a. Remove the four bolts and the control retainer.
Torque: 18 N.m (13 ft. lbs.).

INSTALLATION NOTE: Install a new gasket and control retainer.

b. Remove the select return spring from the retainer.
8. Remove front companion flange, as follows:
a. Using a chisel and hammer, loosen the staked part of the nut.

INSTALLATION NOTE: Stake the lock nut.





b. Using Special Service Tool (SST) 09330-00021 or equivalent, to hold the flange, remove the companion flange lock nut.
Torque: 118 N.m (87 ft. lbs.).





c. Using SST 09950-40010 or equivalent, remove the companion flange.
9. Remove rear companion flange. Remove the rear companion flange in the same way as the front companion flange.

INSTALLATION NOTE:
^ Front companion flange bolts are silver.
^ Rear companion flange bolts are black.

10. Remove extension housing, as follows:
a. Remove the five bolts.
Torque: 12 N.m (108 inch lbs.).

INSTALLATION NOTE: Apply liquid sealer to the bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent

b. Using a plastic hammer, tap the extension housing and remove it.

INSTALLATION NOTE:
^ Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing.





^ Apply FIPG to the extension housing, as shown.
FIPG: THREE BOND 1281 or equivalent.
11. Remove speed sensor drive gear, as follows:
a. Remove the speed sensor drive gear.

INSTALLATION NOTE: Make sure to install the speed sensor drive gear in the correct direction.

b. Using a magnetic finger, remove the ball from the rear output shaft.
12. Separate front case and rear case, as follows:
a. Remove the 12 bolts.
Torque: 28 N.m (20 ft. lbs.).
b. Using a plastic hammer, tap the rear case and separate the front case and rear case.

INSTALLATION NOTE:
^ Shift the high and low clutch sleeve to low side (rear side) and assemble the front case and rear case.
^ Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case.





^ Apply FIPG to the rear case, as shown.
FIPG: THREE BOND 1281 or equivalent

13. Remove straight screw plugs, springs and locking balls, as follows:





a. Using a hexagon wrench, remove the two screws.
Torque: 19 N.m (14 ft. lbs.).

INSTALLATION NOTE: Apply liquid sealer to the plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent





b. Using a magnetic finger, remove the spring and ball from the both holes.
14. Remove front drive fork shaft, fork, spring and stopper, as follows:





a. Using a pin punch and hammer, drive out the 2 slotted spring pins.

NOTE: When the pin is removed from the front drive fork shaft, the shaft will spring loose if the pin punch is removed, so keep the pin punch inserted in the shaft hole.





INSTALLATION NOTE: When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed.





b. Hold the front drive fork shaft in place by hand, when removing the pin punch.
c. Remove the front drive fork shaft, spring, fork and stopper.

INSTALLATION NOTE:





^ Place the front drive shaft fork into the groove of the clutch sleeve.
^ Make sure to install the shift fork and stopper in the correct direction.





d. Using a magnetic finger, remove the straight pin.

INSTALLATION NOTE: Apply gear oil to the straight pin and insert it into the case hole.

15. Remove high and low fork shaft and shift fork, as follows:

INSTALLATION NOTE:





^ Place the high and low shift fork into the groove of the clutch sleeve.
^ Make sure to install the shift fork in the correct direction.

16. Remove rear output shaft, driven sprocket and chain, as follows:





a. Using a snap ring expander, remove the snap ring.
b. Mount the rear case in the vise.

NOTICE: Be careful not to damage the sealing surface.





c. Using a plastic hammer, tap the rear case with pulling the rear output shaft and driven sprocket.

INSTALLATION NOTE: If necessary, heat the rear case to about 70°C (158°F).

d. Remove the chain.
17. Remove synchronizer ring from input shaft, as follows:

INSTALLATION NOTE:
^ Apply gear oil to the synchronizer ring.





^ Align the synchronizer ring slots with the shifting keys, and install it on the high and low clutch hub.

18. Remove separator with oil strainer, as follows:
a. Remove the three bolts and the separator with the oil strainer.
Torque: 7.5 N.m (69 inch lbs.).
b. Remove the O-ring from the oil strainer pipe.

INSTALLATION NOTE: Coat a new O-ring with gear oil and install it to the oil strainer pipe.





19. Remove oil pump body assembly. Remove the three bolts and the oil pump body assembly.
Torque: 7.5 N.m (69 inch lbs.).
20. Remove oil pump drive gear.
21. Remove planetary gear assembly with input shaft.





a. Using a snap ring expander, remove the snap ring.





b. Pull out the planetary gear assembly with the input shaft.

INSTALLATION NOTE: If necessary, heat the front case to about 70°C (158°F).

22. Remove low gear spline piece, as follows:
a. Using a screwdriver, remove the snap ring.

INSTALLATION NOTE: Be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier.





b. Remove the low gear spline piece.





23. Remove needle roller bearing from input shaft

INSTALLATION NOTE: Apply gear oil to the needle roller bearing.

24. Remove input shaft stopper and thrust bearing, as follows:





a. Using a snap ring expander, remove the snap ring.
Snap Ring Thickness:
A: 2.10-2.15 mm (0.0827-0.0846 inch).
B: 2.15-2.20 mm (0.0846-0.0866 inch).
C: 2.20-2.25 mm (0.0866-0.0886 inch).
D: 2.25-2.30 mm (0.0886-0.0906 inch).
E: 2.30-2.35 mm (0.0906-0.0925 inch).
F: 2.35-2.40 mm (0.0925-0.0945 inch).
G: 2.40-2.45 mm (0.0945-0.0965 inch).
H: 2.45-2.50 mm (0.0965-0.0984 inch).
J: 2.50-2.55 mm (0.0984-0.1004 inch).
K: 2.55-2.60 mm (0.1004-0.1024 inch).
L: 2.60-2.65 mm (0.1024-0.1043 inch).
M: 2.65-2.70 mm (0.1043-0.1063 inch).
N: 2.70-2.75 mm (0.1063-0.1083 inch).
O: 2.75-2.80 mm (0.1083-0.1102 inch).
P: 2.80-2.85 mm (0.1102-0.1122 inch)
Q: 2.85-2.90 mm (0.1122-0.1142 inch)
R: 2.90-2.95 mm (0.1142-0.1161 inch).
S: 2.95-3.00 mm (0.1161-0.1181 inch).
U: 3.00-3.05 mm (0.1181-0.1201 inch).

INSTALLATION NOTE: Select a snap ring that will allow 0.05-0.15 mm (0.0020-0.0059 inch) axial play.





b. Remove the input gear stopper, thrust washer and ball.

INSTALLATION NOTE: Apply gear oil to the input gear stopper and thrust washer.





25. Remove input shaft, thrust bearing and race.
26. Remove planetary ring gear.





a. Using a screwdriver, remove the snap ring.

INSTALLATION NOTE: Be sure the end gap of the snap ring is not aligned with the upper side of the case.





b. Remove the plug, spring and pin.
Torque: 19 N.m (14 ft. lbs.).

INSTALLATION NOTE: Apply liquid sealer to the plug.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.





c. Remove the planetary ring gear.

INSTALLATION NOTE: Make sure to install the ring gear in the correct direction.





27. Inspect switches. Check that there is continuity between terminals, as shown.
Switch Position: Push
Specified Condition: No continuity
Switch Position: Free
Specified Condition: Continuity
If operation is not as specified, replace the switch.

INSTALLATION
Installation is in the reverse order of removal.

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