SHIFT FORK, SHIFT ROD AND REVERSE GEAR PARTS ASSEMBLY

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1.  Assemble in the order shown in the figure.

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1	5th/6th shift fork
2	5th/6th shift rod (See Shift Rod Assembly Note.)
3	Roll pin (See Roll Pin Assembly Note.)
4	Interlock pin (short) (See Interlock Pin (Short)/(Long) Assembly Note.)
5	3rd/4th shift fork
6	3rd/4th shift rod (See Shift Rod Assembly Note.)
7	Roll pin (See Roll Pin Assembly Note.)
8	Interlock pin (long) (See Interlock Pin (Short)/(Long) Assembly Note.)
9	Interlock pin (short) (See Interlock Pin (Short)/(Long) Assembly Note.)
10	1st/2nd shift fork
11	1st/2nd shift rod (See Shift Rod Assembly Note.)
12	Roll pin (See Roll Pin Assembly Note.)
13	Interlock pin (long) (See Interlock Pin (Short)/(Long) Assembly Note.)
14	Interlock pin (short) (See Interlock Pin (Short)/(Long) Assembly Note.)
15	Reverse shift rod (See Shift Rod Assembly Note.)
16	Stopper block
17	Roll pin (See Roll Pin Assembly Note.)
18	Detent ball
19	Spring seat
20	Spring
21	Washer
22	Cap plug
23	Reverse idle gear shaft
24	Idle shaft pin (See Idle Shaft Pin Assembly Note.)
25	Oil guide
26	Intermediate housing (See Intermediate Housing Assembly Note.)
27	Friction damper (See Friction Damper Assembly Note.)
28	Washer
29	Bearing
30	Reverse idle gear
31	Washer
32	Washer
33	Bearing race
34	Bearing
35	Reverse gear
36	Reverse synchronizer key spring
37	Reverse clutch hub sleeve (See Reverse Clutch Hub Sleeve Assembly Note.)
38	Reverse shift fork
39	1st/2nd shift rod end
40	Roll pin (See Roll Pin Assembly Note.)
41	3rd/4th shift rod end
42	Roll pin (See Roll Pin Assembly Note.)
43	Reverse synchronizer ring
44	Reverse synchronizer cone (See Reverse Synchronizer Cone Assembly Note.)
45	C-washer (See C-washer Assembly Note.)
46	Washer
47	Snap ring
48	5th/6th shift rod end
49	Roll pin (See Roll Pin Assembly Note.)
50	Breather

Shift Rod Assembly Note

1.  Assemble the shift rods to the bearing housing with the shift rod grooves shown in the figure pointed towards the shift check mechanism side.

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Roll Pin Assembly Note

1.  Assemble the new roll pins using a pin punch and a hammer.

Note

•  The tap-in amount of the roll pins varies depending on their location of use. Verify the type with the table, and assemble as shown in the figure.

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Roll pin location of use	Tap-in amount type
5th/6th shift fork	Type A
1st/2nd shift fork	Type A
3rd/4th shift fork	Type A
Stopper block	Type A
1st/2nd shift rod end	Type B
3rd/4th shift rod end	Type B
5th/6th shift rod end	Type B
Reverse shift fork	Type B

Interlock Pin (Short)/(Long) Assembly Note

1.  Assemble the interlock pins (short)/(long) to the positions on the bearing housing shown in the figure using a magnet.

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Idle Shaft Pin Assembly Note

1.  Assemble the new O-ring to the end of the idle shaft pin, and apply transmission oil (long-life gear oil IS).

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2.  Assemble the idle shaft pin through the new washer.

Intermediate Housing Assembly Note

1.  Apply silicone sealant TB1217E to the intermediate housing as shown in the figure.

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2.  Assemble the intermediate housing.

Friction Damper Assembly Note

1.  Assemble the new friction damper to the reverse idle gear using the SST and the press.

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Reverse Clutch Hub Sleeve Assembly Note

1.  Assemble so that the reverse clutch hub sleeve marking is pointing toward the extension housing side.

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Reverse Synchronizer Cone Assembly Note

1.  Assemble the reverse synchronizer cone using the SSTs and a hammer.

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C-washer Assembly Note

1.  Assemble the removed C-washer during disassembly to the washer, and assemble the snap ring.

2.  Measure the clearance between the reverse synchronizer cone and C-washer with a thickness gauge.

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•  If not within the standard, adjust the clearance by choosing the proper C-washer.

C-washer thickness (mm {in})
3.1 {0.123}
3.2 {0.126}
3.3 {0.130}
3.4 {0.134}

3.  Assemble the adjusted C-washer to the washer and assemble the new snap ring.