Transmission Assemble

Transmission Assemble





1. Using a drive tool, install a new bearing, if equipped.





2. Using locking pliers, install the bearing snap ring, if equipped.





3. Using a drive tool, if required, install a new extension oil seal.





4. Using a driving tool, install a new retaining oil seal, if required.





5. Using a drive tool or hydraulic press, install the drive shaft tapered bearing taper.





6. Install the drive shaft interior bearing roller cage.





7. Install the main shaft assembly. Fasten it to the synchronizer, lifting with the help of a cord in one hand and pushing with the other hand.





8. Install the tapered bearing race.





9. Install the drive shaft, positioning the shaft lubrication grooves with the clutch ring.





10. Install the new spacers and bearing race. Add spacers for more play and remove spacers for less play.

Axial play should be 0.025-0.127 mm (0.001-0.005 in).





11. Install the bearing retainer, locating the bearing retainer position to the bore holes, which are the position of the lubrication bores.





Caution:
Refer to Fastener Caution Fastener Caution.

12. Tighten the 4 screws to 16-21 Nm (12-16 lb ft).





13. Install the transmission over 2 supports and attach the tracking sphere.





14. Install the washer.





15. Install the 2 roller bearings and the spacer.





16. Install the 5th gear synchronizer with the fork.





17. Install the lubricated synchronization ring and the 5th gear taper.





18. Using locking pliers, install the 5th gear clutch ring.





19. Using a dial indicator, observe the axial play.





20. Install the roll pin.





21. Position the speedometer gear.





22. Install the speedometer gear tracking sphere.





23. Install the yoke spacer.





24. Install the cover.





25. Install the 2 guide screws in order to align the cover.





26. Tighten the rest of the 8 screws to 57-68 Nm (42-50 lb ft).





27. Install the main shaft yoke washer and nut.





28. Tighten the main shaft nut to 150-170 Nm (110-125 lb ft).





29. Position the transmission, and install a dial indicator in order to measure the axial play. Add spacers for more play and remove spacers for less play.

The axial play should be 0.025-0.127 mm (0.001-0.005 in).





30. Once you have achieved the axial play, proceed to the final assembly. Clean the bearing retainer surface and apply gasket maker.





31. Install the bearing retainer, for the final assembly.





32. Apply a Teflon(R) sealer to the screw threads.

33. Install the screws and tighten to 34-40 Nm (25-30 lb ft).





34. Once the axial play is achieved, proceed to the final assembly. Clean the cover surface and apply gasket maker.





35. Apply a Teflon(R) sealer to the screw threads.

36. Install the screws and tighten to 57-68 Nm (42-50 lb ft).





37. Install the main shaft yoke onto the main shaft.





38. Tighten the NEW main shaft nut to 150-170 Nm (110-125 lb ft).





39. Install the vehicle speed sensor, if necessary.





40. Tighten the vehicle speed sensor.

Caution:
Use the correct oil. The transmission could be severely damaged if the correct oil is not used.

41. Add 3.5 liters (3.7 quart) of oil 1 ATF synthetic oil.