Assembly

5TH And Reverse Gear:

Torque Specifications




Assembly Note
Reverse Gear
1. Install the reverse idler gear and shaft with a spacer on each side of the gear.
2. Install the counter reverse gear (chamfer side forward) and spacer.
3. Install the thrust washer, reverse gear, synchronizer ring, inner race, needle bearing, and clutch hub assembly.




4. Shift into 1st gear and reverse gear to lock the rotation of the mainshaft.
5. Install a new locknut and tighten it with the SST.

Tightening torque: 128 - 196 N.m (13 - 20 m-kg, 94 - 145 ft-lb)




6. Check the clearance between the synchronizer key and the exposed edge of the synchronizer ring. If the clearance is not as specified, adjust with the thrust washers at the mainshaft bearing front and rear.

Clearance: 2.0 mm (0.079 in) max.

Available thrust washer thicknesses: 2.5 mm (0.098 in), 3.0 mm (0.118 in), 3.5 mm (0.138 in)

CAUTION: The total combined thickness of the front and rear thrust washers should equal 6.0 mm (0.236 in).




7. Stake the locknut into the mainshaft keyway.




5th gear
1. Install the synchronizer ring and 5th gear.

NOTE: If the 5th gear is replaced, a new retaining ring must be installed on the inner surface of the 5th gear.




2. Install the steel ball and thrust lock washer.
3. Install 3.0 mm (0.118 in) thick C washers and hold them with the retaining ring.




4. Push the C washers toward 5th gear and measure the clearance between the C washers and thrust lock washer.
If the clearance is not as specified, select the proper thrust lock washer.

Standard: 0.1 - 0.2 mm (0.004 - 0.008 in)

Available thrust washer thicknesses:
6.4 mm (0.252 in), 6.5 mm (0.256 in),
6.6 mm (0.260 in), 6.7 mm (0.264 in)




Shift fork and rod

NOTE:
A simple way to identify the shift rods is the following:
- The 3rd/4th shift rod is the longest.
- The 5th/Rev shift rod has a hole for the shift fork at the rear of the rod.

When installing the shift rods, set the detent ball grooves toward the ball side.




1. Slide the 1st/2nd shift rod into the case.
2. Secure the 1st/2nd shift fork to the rod with the spring pin.

CAUTION: The spring pin is to be installed with the groove of the pin as shown in the image.




NOTE: The interlock pins are to be installed as shown in the image.




3. Slide the two SST into the transmission case to guide the interlock pins, and insert the first pin.
4. Remove the 3rd/4th shift fork guide from the case.
5. Slide the 3rd/4th shift rod into the case.
6. Secure the 3rd/4th shift rod to the fork with the spring pin. Insert the remaining interlock pin, and remove the SST.




7. Install the 5th/Rev fork on the clutch hub, and slide the reverse and 5th shift rod into the transmission case.
8. Secure the 5th/Rev shift fork to the shift rod with the spring pin.




9. Install the two blind covers and gaskets.

Tightening torque: 7.8 - 11 N.m (80 - 110 cm-kg, 69 - 95 in-lb)

10. Install the three detent balls, three springs, and three cap bolts.

Tightening torque:
(A) 39 - 59 N.m (4.0 - 6.0 m-kg, 29 - 43 ft-lb)
(B) 19 - 25 N.m (1.9 - 2.6 m-kg, 14 - 19 ft-lb)