Case: Service and Repair

DISASSEMBLY
1. Remove back up light switch (1) and locating spring bolts (2).
2. Take out locating springs and locating balls.





3. Remove 2 spring pins and pull out low speed gear shift shaft (3) and high speed gear shift shaft (2) in that order.
4. Using Special Tool (A) 09922-85811, pull out reverse gear shift shaft (1), then disconnect fork from shaft removing spring pin.

NOTE: Make sure that remaining gear shift shafts are all neutral position when removing a gear shift shaft.

5. Take out rubber plugs and 2 interlock balls from case.
6. Remove interlock pin from high speed gear shift shaft.





INSPECTION
1. Using feeler gauge, check clearance between fork (1) and sleeve (2) and replace those parts if it exceeds limit.
Clearance "a": 1.0 mm (0.039 inch) Maximum
2. Insert each gear shift shaft into case and check that it moves smoothly. If it doesn't, correct by using oilstone, reamer or the like.





3. Check gear shift shaft for excessive wear and correct or replace as necessary.





4. Check free length of each locating spring and replace if it is below service limit.
Free length:
Standard: 27.0 mm (1.063 inch)
Service limit: 24.0 mm (0.945 inch)





ASSEMBLY
Interlock system is as shown in the figure.
Assemble its parts according to procedure as described.
(1) Locating ball
(2) Rubber plug
(3) Reverse gear shift shaft
(4) Interlock ball
(5) Interlock pin
(6) High speed gear shift shaft
(7) Low speed gear shift shaft





1. With fork installed to reverse gear shift shaft (1), install it into case and put in interlock ball (2).





NOTE:
- Reverse gear shift fork spring pin (1) is different from other pins (2) in length. It is longer than other pins.





- When pressing spring pin (1) into reverse gear shift fork (2), do not allow to go all the way in, but leave its end protruded as much as the length shown in the figure.





2. With interlock pin fit to high speed gear shift shaft (1), insert it into case and set fork with spring pin and then put in interlock ball (2).

NOTE:
- Note that high speed gear shift shaft can't be inserted unless reverse gear shift shaft (a) is placed at neutral position.
- When inserting high speed gear shift shaft, use care not to drop interlock pin.





3. With both reverse and high speed gear shift shafts placed at neutral position, insert low speed gear shift shaft (1) into case and fix fork with spring pin. Then apply sealant to rubber plugs (2) and fit them in.





4. Confirm that interlock system operates properly by checking the following:
- When shifted to low position (or 2nd position), shifting of 3rd/4th or 5th/Rev. position is not available.





- When shifted to reverse position (or 5th position), shifting of 1st/2nd or 3rd/4th position is not available.





5. Install locating balls and locating springs and then set washers and bolts.
Tightening Torque (a) 28 Nm (20.0 ft. lbs.)