Reassembly

Top Gear Shaft, Mainshaft Gear And Counter Gear:

MINOR COMPONENTS

Important Operations




2. Needle Bearing
3. 2nd Gear
1. Apply the engine oil to the 2nd needle bearing and the 2nd gear.
2. Install the needle bearing and the 2nd gear to the mainshaft.
The dog teeth of the 2nd gear must be facing the rear side of the transmission.




5. 1st-2nd Synchronizer Assembly
1. Check that the inserts are fit properly into the insert grooves in the blocker ring and that the insert spring is matched to the insert keys as shown in this figure. Then check that the clutch hub and sleeve slide smoothly.
(1) : Insert key
(2) : Insert spring
(3) : Clutch hub




2. Install the synchronizer assembly on the shaft, so that the face of the clutch hub with oil groove : (2) is turned to the 2nd gear side (forward).




7. Needle Bearing Collar
Use a bench press and the collar installer to install the needle bearing collar.
Collar Installer : J-33851




8. Needle Bearing
9. 1st Gear
1. Apply the engine oil to the 1st needle bearing and the 1st gear.
2. Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 1st gear must be facing the front side of the transmission.




10. 1st Gear Thrust Washer
Install the thrust washer to the mainshaft
The thrust washer oil groove must be facing the front of the transmission.




11. Mainshaft Ball Bearing
1. Apply the engine oil to the ball bearing inside circumference.
2. Use a bench press and the bearing installer to install the bearing.
The bearing snap ring groove must be facing the front of the transmission.
Bearing Installer : J-22912-01




12. Needle Bearing
13. 3rd Gear
1. Apply the engine oil to the 3rd needle bearing and the 3rd gear.
2. Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 3rd gear must be facing the front side of the transmission.




15. 3rd-Top Synchronizer Assembly
1. Apply the recommended lubricating oil to the clutch hub spline.
2. Install the synchronizer assembly to the mainshaft
The sleeve light chamfering (1) and the clutch hub heavy boss (2) must be facing the rear of the transmission.




16. Mainshaft Snap Ring
1. Select the snap ring which will provide the minimum clearance between the mainshaft and the snap ring.
There are four snap ring sizes available.
The snap rings are numbered to indicate their thickness.

Mainshaft and Snap Ring Clearance Standard: 0 - 0.05 (0.002) mm (in)

Snap Ring Availability:

2. Use a pair of snap ring pliers to install the snap ring to the mainshaft.




19. Top Gear Shaft
20. Ball Bearing
Use a bench press and the installer to install the ball bearing to the top gear shaft.
The snap ring groove must be facing the front of the transmission.
Bearing Installer : J-22912-01




25. Rear Ball Bearing
Use a bench press and the bearing installer to install the bearing to the counter gear.
Bearing Installer : J-22912-01




REVERSE GEAR AND 5TH GEAR

Important Operations




1. Intermediate Plate
4. Reverse Idler Shaft
1. Install the reverse idler shaft to the intermediate plate.
2. Tighten the reverse shaft bolt to the specified torque.

Idler Shaft Bolt Torque: 2.0 (14.5/142.1) kg-m(lb-ft/N-m)




3. Set the mainshaft with gear assembly (1) and the counter gear assembly (2) to the holding fixture (3).
Holding Fixture : J-29768
4. Place the holding fixture (with the mainshaft and the counter shaft) in a vise.
5. Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6. Install the intermediate plate to the mainshaft and the counter gear ball bearings.




6. Reverse Idler Gear
8. Lock Nut
1. Apply the engine oil to the idler shaft and the reverse gear inside circumference.
2. Tighten the reverse gear lock nut to the specified torque.

Lock Nut Torque: 11.1 ± 1.0 (79.6 ± 7.2/107.8 ± 9.8) kg-m(lb-ft/N-m)




9. Thrust Washer
1. Apply the engine oil to both sides of the thrust washer.
2. Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the front side of the transmission.




13. Reverse - 5th Synchronizer Assembly
1. Apply the engine oil to the clutch hub spline.
2. Install the synchronizer assembly to the mainshaft.
The sleeve heavy chamfer (1) and the insert short side (2) must be facing the rear side of the transmission.




14. Mainshaft Lock Nut and Washer
1. Install a new lock nut and washer to the mainshaft. Never reinstall the used lock nut and washer.
2. Use the lock nut wrench to tighten the lock nut to the specified torque.

Lock Nut Wrench : J-36629
Lock Nut Torque: 12 (86.8/117.6) kg-m(lb-ft/N-m)




18. Thrust Washer and Lock Ball
19. Thrust Ring
20. Snap Ring
1. Install the thrust washer with lock ball together with the thrust ring to the mainshaft.
2. Install the two pieces of the thrust ring to the main shaft.
3. Use a pair of snap ring pliers to install the snap ring.

5th Gear And Thrust Washer Clearance:

4. Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer.
If required, replace the existing thrust washer with a new thrust washer to bring the clearance to specification.

Thrust Washer Availability:

There are six thrust washer sizes available.
4. Position the thrust ring snap ring gap (1) and the thrust ring gap (2) so that they are separated at a 90 degree angle.

24. Self Lock Nut and Washer
Tighten the lock nut to the specified torque.

Self Lock Nut Torque: 11.1 ± 1.0 (79.6 ± 7.2/107.8 ± 9.8) kg-m(lb-ft/N-m)




DETENT AND SHIFT FORK ASSEMBLY

Important Operations




2. 1st-2nd Shift Arm
3. 3rd-4th Shift Arm
7. Rev.-5th Shift Arm
1. Hold a round bar against the shift rod end lower face to protect it against damage.
2. Use a spring pin installer to install the new spring pin to the shift arm and the shift rod.
Never reinstall the used spring pins.




11. Detent Spring Plate
Tighten the detent spring plate bolts to the specified torque.

Detent Spring Plate Bolt Torque: 2.0 ± 0.2 (14.5 ± 1.4/19.6 ± 1.96) kg-m(lb-ft/N-m)




MAJOR COMPONENTS

Important Operations




2. Rear Cover with Oil Seal
1. Align the pins at the lower side of the rear cover with the holes in the lower side of the intermediate plate.
2. Install the rear cover to the intermediate plate.
3. Tighten the rear cover bolts to the specified torque.

Rear Cover Bolt Torque: 2.0 ± 0.2 (14.5 ± 1.4/19.6 ± 1.96) kg-m(lb-ft/N-m)

NOTE: Take care not to twist or puncture the oil seal during the installation procedure.




3. Transmission Case
4. Bearing Snap Ring
1. Apply the engine oil to the transmission case top gear shaft ball bearing fitting faces.
2. Install the transmission case to the intermediate plate.
3. Pull the top gear shaft from the transmission case until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face.
4. Use a pair of snap ring pliers to install the snap ring to the ball bearing.




5. Belleville Spring
The belleville spring should be so installed that its dished face is turned to the bearing outer race.
(1) : Transmission case
(2) : Front cover
(3) : Belleville spring