Case Components

Case Components: Disassembly and Assembly

Disassembly

Case Components

1) Remove clips from PNP switch and back-up lamp switch.

2) Remove PNP switch, back-up lamp switch and plungers from rear extension (or OD gear case).
3) Remove control housing bolts, and then remove control housing and gasket from rear extension (or OD gear case).

4) Remove return spring plug, return spring and return spring plunger from rear extension (or OD gear case).

CAUTION:
Do not reuse return spring plug.

5) Remove rear oil seal from OD gear case using Tool (for 4WD models).

CAUTION:
Do not damage OD gear case.

6) Remove retaining pin using suitable tool, and then remove striking arm from striking rod assembly.

7) Remove rear extension (or OD gear case) bolts, and then remove rear extension (or OD gear case) from adapter plate using suitable tool.

8) Remove rear extension oil gutter bolt, and then remove rear extension oil gutter and cap from rear extension. (For 2WD models)

9) Remove dust seal and rear oil seal from rear extension using suitable tool. (For 2WD models)

CAUTION:
Be careful not to damage rear extension.

10) Remove counter end bearing from rear extension (or OD gear case) using suitable tool.

CAUTION:
Be careful not to damage rear extension (or OD gear case).

11) Remove withdrawal lever ball pin and washer from front cover.

12) Remove front cover bolts, and then remove front cover and front cover gasket from transmission case.

13) Remove front cover oil seal from front cover using suitable tool.

CAUTION:
Be careful not to damage front cover.

14) Remove baffle plate nut from transmission case.

15) Remove snap ring from main drive gear bearing using suitable tool.

16) Remove pivot bolt and check shift pin from transmission case.

CAUTION:
Do not reuse pivot bolt and check shift pin.

17) Remove transmission case from adapter plate.

18) Remove counter front bearing from transmission case.

19) Remove oil gutter from transmission case.

20) Remove filler plug and gasket from transmission case.

CAUTION:
Do not reuse gasket.

Assembly

Case Components

1) Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft assembly. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
2) Install fork rods and shift forks. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
3) Install oil gutter to transmission case.

4) Install counter front bearing to transmission case.

CAUTION:
Apply multi-purpose grease to counter front bearing.

5) Apply recommended sealant to mating surface of transmission case as shown.

7) Install snap ring to main drive gear bearing using suitable tool.

CAUTION:
Do not reuse snap ring.

8) Tighten baffle plate nut to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

9) Tighten baffle plate bolt to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

10) Install front cover oil seal to front cover using Tool.

CAUTION:
- Do not reuse front cover oil seal.
- Apply multi-purpose grease onto oil seal lip.
- When installing, do not incline front cover oil seal.

11) Install front cover according to the following.
a) Install front cover gasket and front cover to transmission case.

CAUTION:
Do not reuse front cover gasket.

b) Temporarily tighten 2 bolts in the positions shown.
c) Temporarily tighten remaining 9 bolts.
d) Tighten bolts to the specified torque in order as shown. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

CAUTION:
Do not reuse bolts indicated as (A) in the figure.

12) Install washer to withdrawal lever ball pin, and then install it to front cover. Tighten withdrawal lever ball pin to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

13) Install counter end bearing to rear extension (or OD gear case) using suitable tool [32 mm (1.26 in) dia.].

CAUTION:
- Do not reuse counter end bearing.
- Apply gear oil to counter end bearing.
- Install counter end bearing with maker stamp at upper side.

14) Install rear extension oil gutter according to the following. (For 2WD models)
a) Install cap to rear extension oil gutter.

b) Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
15) Install rear oil seal (1) to rear extension (or OD gear case) using Tool (A).

CAUTION:
- Do not reuse rear oil seal.
- When installing, do not incline rear oil seal.

(B): Seal lip
16) Install dust seal (1) to rear extension using Tool (A) (for 2WD models).

CAUTION:
- Do not reuse dust seal.
- When installing, do not incline dust seal.

(B): Seal lip
17) Apply recommended sealant to mating surface of rear extension as shown.

- Use Genuine Silicone RTV or the equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.

18) Install rear extension (or OD gear case) to adapter plate, and then tighten bolts to the specified torque in order as shown. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

19) Install check shift pin and pivot bolt to transmission case, and then tighten them to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

CAUTION:
Do not reuse check shift pin and pivot bolt.

20) Install return spring plunger, return spring and return spring plug to rear extension (or OD gear case), and then tighten return spring plug to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

CAUTION:
- Do not reuse return spring plug.
- Apply gear oil to return spring plunger.

21) Install PNP switch and back-up lamp switch according to the following.
a) Install plunger to rear extension (or OD gear case).

b) Apply recommended sealant to threads of PNP switch and back-up lamp switch.
- Use Genuine Silicone RTV or the equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.
c) Install PNP switch and back-up lamp switch to rear extension (or OD gear case), and tighten them to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
22) Install clips to PNP switch and back-up lamp switch.

CAUTION:
- Thread harness through the notch of clip.
- Thread the harness as shown.

23) Install striking arm according to the following.
a) Install striking arm to striking rod assembly.

b) Install retaining pin to striking arm using suitable tool.

CAUTION:
Do not reuse retaining pin.

24) Install control housing according to the following.
a) Install gasket and control housing to rear extension (or OD gear case).

CAUTION:
Do not reuse gasket.

b) Tighten bolts to the specified torque in order as shown. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
25) Install gasket to drain plug, and then install it to transmission case. Tighten drain plug to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

CAUTION:
Do not reuse gasket.

26) Install gasket to filler plug, and then install it to transmission case. Tighten filler plug to the specified torque. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.

CAUTION:
- Do not reuse gasket.
- After oil is filled, tighten filler plug to specified torque.