Transmission Reassembly

Transmission Reassembly

NOTE: Prior to reassembling, clean all parts in solvent, dry them, and apply manual transmission fluid (MTF) to any contact surfaces.

1. Install the magnet (A) and differential assembly (B).





2. Install the 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing (C).

NOTE: Install the spring washer in the direction shown.





3. Apply vinyl tape to the mainshaft splines (D) to protect the seal. Install the mainshaft assembly (E) and countershaft assembly (F) into the shift fork assembly (G), as an assembly.
4. Install the reverse shift fork (A).





5. Install the reverse idler gear (A) and reverse gear shaft (B) by aligning the mark (C) with the reverse gear shaft hole (D).





6. Install the reverse lock cam (A).





7. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M, and 72 mm shim into the transmission housing (C).





8. Clean any dirt and oil from the transmission housing sealing surface.
9. Apply liquid gasket, P/N 08718-0001 evenly to the mating surface of the transmission housing and the clutch housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





10. Install the 14 x 20 mm dowel pins (A).





11. Set the tapered cone ring (B) as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.
12. Lower the transmission housing the rest of the way as you expand the 72 mm snap ring (C). Release the snap ring so it seats in the groove of the countershaft bearing.
13. Make sure the 72 mm snap ring is securely seated in the groove of the countershaft bearing.

Dimension (1) as installed: 3.3 - 6.0 mm (0.13 - 0.24 in.)

14. Apply liquid gasket, P/N 08718-0001, evenly to the threads of the 32 mm searing cap (D) mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

15. Install transmission hangers A, B, and the 8 mm flange bolts, finger-tight.





16. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.





17. Clean any dirt or oil from the change lever assembly sealing surface.
18. Apply liquid gasket, P/N 08718-0001, evenly to the mating surface of the change lever assembly and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
^ Allow it to cure at least 30 minutes after assembly before filling the transmission with MTF





19. Install the 8 x 14 mm dowel pins (A) and the change lever assembly (B).





20. Apply liquid gasket, P/N 08718-0001, evenly to the mating surface of the threads of the inter lock bolt and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

21. Install the drain plug (A), and 10 mm flange bolt (B) with new washers. Install the filler plug (C) finger tight.





22. Apply MTF to the new O-ring (D). Then install the new O-ring, the plain washer (E), and the output shaft (countershaft) speed sensor (F).
23. Install the detent bolts, springs, and steel balls (A) with new washers (B).





24. Apply liquid gasket, P/N 08718-0001 evenly to the threads of the back-up light switch mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
^ If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
^ If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

25. Install the transmission hanger (C).
26. Install the 20 mm bolt (A) and 20 mm washer (B).





27. 2WD: Apply MTF to the new O-ring (A). Then install the new O-ring and the side cover (B).





28. 4WD: Apply MTF to the new O-ring (A). Then install the new O-ring, 10 x 20 mm dowel pin (B), and the transfer assembly (C).