Part 1

MANUAL TRANSMISSION UNIT

Components:

Components:

Components:

Components:

REASSEMBLY





1. INSTALL OUTPUT SHAFT ASSEMBLY
a. Apply gear oil to the sliding part of the output assembly.
b. Using a plastic hammer, install the output shaft assembly by tapping the intermediate plate.





2. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING
a. Using a snap ring expander, install the output shaft bearing shaft snap ring onto the output shaft.





3. INSTALL INPUT SHAFT ASSEMBLY
a. Apply gear oil to the input shaft assembly and synchronizer ring No. 2, and install them onto the output shaft.

NOTICE:
^ Install the synchronizer ring No. 2 so that its groove fits into the synchromesh shifting key No. 2.
^ Check that the input shaft assembly rotates smoothly.





4. INSTALL COUNTER GEAR
a. Provisionally install the counter gear assembly onto the intermediate plate.





5. INSTALL COUNTER SHAFT CENTER BEARING
a. Using SST and a hammer, install the new counter shaft center bearing onto the intermediate plate.
SST 09316-60011 (09316-00011)

HINT: Remove the bearing while tapping the tip of the counter gear so that the counter gear assembly is not pushed forward into the side wall of the output shaft gear.





6. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY
a. Apply gear oil to each sliding part of the reverse idler gear and the reverse idler gear shaft, and install them onto the intermediate plate.

NOTICE: Orient the groove side of the reverse idler shaft to the rear side and install it from the rear side.





7. INSTALL OUTPUT SHAFT REAR BEARING RETAINER
a. Install the output shaft rear bearing retainer into the groove of the reverse idler gear shaft with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





8. INSTALL 5TH GEAR THRUST WASHER PIN
a. Apply MP grease to the 5th gear thrust washer pin, and install it onto the counter gear.





9. INSTALL 5TH GEAR THRUST WASHER
a. Apply gear oil to the 5th gear thrust washer, and install it onto the counter gear.

NOTICE: Install the thrust washer so that its chamfer side faces to the front side.





10. INSTALL NO. 3 TRANSMISSION HUB SLEEVE
a. Apply gear oil to the sliding part of transmission hub sleeve No. 3, and install it onto the counter shaft 5th gear.

NOTICE: Make sure that the transmission hub sleeve No. 3 and counter 5th gear are oriented in the correct direction.

b. Install the 2 synchromesh shifting keys No. 3 and the 2 synchromesh shifting key springs onto the counter shaft 5th gear.





c. Using a snap ring expander, install the bearing shaft snap ring onto the counter 5th gear.





11. INSTALL COUNTER 5TH GEAR BEARING
a. Apply gear oil to the counter 5th gear bearing and install it onto the counter 5th gear.





12. INSTALL COUNTER SHAFT 5TH GEAR
a. Apply gear oil to the counter 5th gear and transmission hub sleeve No. 3 assembly, and install them onto the counter gear.





13. INSTALL NO. 3 SYNCHRONIZER RING OUTER
a. Apply gear oil to the synchronizer ring outer No. 3, and install it onto the counter gear.

NOTICE: Install the synchronizer ring outer No. 3 so that its groove fits into the synchromesh shifting key No. 3.





14. INSTALL NO. 5 GEAR SPLINE PIECE
a. Using SST and a press, install the gear spline piece No. 5 onto the counter gear.
SST 09316-60011 (09316-00011)

NOTICE: Check that the gear rotates smoothly.





15. INSTALL COUNTER GEAR REAR SHAFT SNAP RING
a. Select the counter gear rear shaft snap ring so that the thrust gap between gear spline piece No. 5 and counter gear rear shaft snap ring is within the specified values, and using a brass bar and a hammer, install it onto the counter gear.





Standard clearance: 0.1 mm (0.0039 inch) or less





16. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, check the thrust clearance of the counter 5th gear.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)





17. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, check the counter 5th gear radial clearance.
Standard clearance: 0.015 to 0.068 mm (0.0006 to 0.0027 inch)
If the clearance is out of specification the counter 5th gear bearing.





18. INSTALL OUTPUT SHAFT REAR BEARING
a. Using SST and a press, install the new spacer and output shaft rear bearing onto the output shaft.
SST 09309-35010





19. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING
a. Select an output shaft bearing shaft snap ring so the thrust gap between the snap ring and the bearing is within the specified values. Use a brass bar and hammer to install it onto the output shaft.





Standard clearance: 0.1 mm (0.0039 inch) or less





20. INSTALL REVERSE SHIFT ARM BRACKET
a. Install the reverse shift arm bracket onto the intermediate plate with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





21. INSTALL REVERSE SHIFT FORK
a. Install the reverse shift arm onto the reverse shift fork. Using a screwdriver and a hammer, install the new reverse shift arm end shaft ring.





b. Install the tip of the reverse shift arm onto the reverse idler gear. Align the cut end of the reverse shift arm with the reverse shift arm bracket pin, and install them.





22. INSTALL 5TH SHIFT ARM SHAFT
a. Install the reverse shift fork return compression spring and the reverse shift fork ball into the reverse shift fork.





b. Apply gear oil to the sliding part of the 5th shift arm shaft.
c. Using a screwdriver, install the 5th shift arm shaft by pushing the reverse shift fork ball gently.





d. Using a brass bar and a hammer, install the shift fork shaft snap ring onto the 5th shift arm shaft.





23. INSTALL REVERSE SHIFT FORK SHAFT
a. Install the reverse shift fork ball into the reverse shift fork.





b. Install the shift interlock No. 1 roller onto the intermediate plate.





c. Install the shift fork No. 3 onto the transmission hub sleeve No. 3 and the reverse shift fork shaft onto the intermediate plate from the front side.





d. Using a brass bar and a hammer, install the shift fork shaft snap ring onto the reverse shift fork shaft.





e. Using a pin punch (5 mm) and a hammer, install the shift fork set slotted spring pin into the gear shift fork No. 3.





24. INSTALL NO. 1 GEAR SHIFT FORK SHAFT
a. Install the shift interlock No. 1 roller onto the intermediate plate.





b. Install the gearshift fork No. 1 onto the reverse gear.





c. Install the gear shift fork shaft No. 1 onto the intermediate plate from the rear side.





d. Install the new shift fork set bolt onto the gearshift fork No. 1.
Torque: 19.5 Nm (199 kgf-cm, 14 ft. lbs.)





e. Using a brass bar and a hammer, install the shift fork shaft snap ring onto the gear shift fork shaft No. 1 .





25. INSTALL NO. 2 GEAR SHIFT FORK SHAFT
a. Install the shift interlock pin (ball) and shift interlock No. 1 roller into the intermediate plate.





b. Install the gearshift fork No. 2 onto the transmission hub sleeve No. 2.





c. Apply gear oil to the gear shift fork shaft No. 2, and install it onto the intermediate plate from the rear side.





d. Install the new shift fork set bolt onto the gear shift fork No. 2.
Torque: 19.5 Nm (199 kgf-cm, 14 ft. lbs.)





e. Using a brass bar and a hammer, install the shift fork shaft snap ring onto the gear shift fork shaft No. 2.