Transmission Case
Transmission Case
Major Component (4X2)
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case and drain the lubricant.
3. Remove the clutch release bearing (1) from the transmission case
4. Remove the snap pin.
Remove the shift fork pin and shift fork (2) from the fulcrum bridge.
5. Remove the fulcrum bridge bolts.
Remove the fulcrum bridge (3) from the transmission case.
Remove the front cover (4) and gasket from the transmission case.
6. Remove snap ring (5) fixing counter front bearing.
7. Use a pair of snap ring pliers to remove the snap ring (6) fixing top gear bearing.
8. Remove the speedometer sensor (7).
Remove the plate (7).
Remove the driven gear bushing and driven gear (7).
Note: Apply a reference mark to the driven gear bushing before removal.
9. Remove gear control box assembly (8).
10. Remove the rear cover assembly from the transmission case.
11. Remove 1-2 and 3-4 indicator switch (10), pin (10) and ball (10).
Remove intermediate plate with gear assembly (11) from transmission case (12).
Reassembly
1. Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transmission case (12), intermediate plate (11) and rear cover (9) fitting surfaces.
2. Install the intermediate plate with gear assembly (11) to the transmission case (12).
Pull out the top gear shaft until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or stress.
3. Tighten the transmission rear cover bolts to the specified torque.
Torque: 37 Nm (27 ft. lbs.)
Note: Notes When Tightening the Bolt:
- After cleaning the bolt hole, dry it thoroughly with air.
- After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 24V or its equivalent before tightening it
4. Install a new gasket and gear control box assembly (8).
Install the harness clips and brackets and then tighten four new gear control box bolts to the specified torque.
Torque: 20 Nm (14 ft. lbs.)
5. Install the O-ring (4) to the speedometer driven gear bushing (3)
Install the driven gear to the speedometer driven gear bushing (3)
6. Install the speedometer driven gear assembly (7) to the transmission rear cover (9)
Install the plate (1) to the transmission rear cover (9)
Torque: 15 Nm (11 ft. lbs.)
7. Install the speedometer sensor (7)
Torque: 27 Nm (20 ft. lbs.)
8. Install top gear bearing snap ring (6) and counter front bearing snap ring (5).
- Use a pair of snap ring pliers to install the snap rings to the mainshaft and countershaft.
- The snap rings must be fully inserted into the bearing snap ring groove.
9. Install front cover (with oil seal) (4).
Front Cover Oil Seal Replacement
- Remove the oil seal from the front cover.
- Apply engine oil to a new oil seal outer circumference.
- Apply recommended grease to the oil seal lip.
- Use the oil seal installer J-26540 to install the oil seal to the front cover.
10. Install a new packing and front cover (4) to the transmission case.
Note: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
- After the bolt hole, dry it thoroughly with air.
- After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 24V or its equivalent before tightening it
- Tighten six new front cover bolts to the specified torque.
Torque: 25 Nm (18 ft. lbs.)
11. Install the fulcrum bridge (3) to the transmission case.
Tighten three fulcrum bridge bolts to the specified torque.
Torque: 38 Nm (28 ft. lbs.)
12. Apply grease to the pin hole inner circumferences and thrust surfaces.
Attach the shift fork (2) to the fulcrum bridge (3) by inserting the shift fork pin from the bottom side of the fulcrum bridge.
Install the washer and snap pin.
13. Apply grease to the areas as shown in the figure.
- Install the release bearing (1) to the shift fork (2) in the proper direction.
Note: Ensure release bearing is properly positioned during installation, as shown in the figure.