MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE ASSEMBLY

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1. Assemble in the order indicated in the table.

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1 | Transmission case
2 | Countershaft component (See Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note.)
3 | Mainshaft component (See Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note.)
4 | Maindrive gear (See Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note.)
5 | Countershaft front bearing
6 | Countershaft rear bearing
7 | Maindrive gear bearing race
8 | Mainshaft bearing race
9 | Bearing cover
10 | Front oil seal (See Front Oil Seal Assembly Note.)
11 | Bearing shim
12 | Bearing shim
13 | Oil baffle
14 | Front cover (See Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note.)
15 | Front cover No.2

Front Oil Seal Assembly Note

1. Install the oil seal to the front cover using the SST.

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Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note

1. Install the countershaft component.

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2. Install the mainshaft component.

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3. Insert the maindrive gear component from the front cover hole and assemble to the mainshaft component.

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4. Install the countershaft front and center bearing.

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5. Install the maindrive gear bearing race and mainshaft center bearing race.

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6. Install the bearing cover with the arrow pointing to the top of the case.

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  Tightening torque:

  17.7—26.4 N·m {1.81—2.69 kgf·m, 13.1—19.4 ft·lbf}

7. Select the mainshaft component and countershaft component bearing shims according to the following procedure.

  (1) Set the clutch housing side upward and level the transmission case.
    Caution
    • Securely assemble the mainshaft, maindrive gear component, and countershaft component so that there is no looseness or play.

  (2) Using a depth gauge, measure the maindrive gear bearing outer race height A.

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  (3) Using a depth gage, measure the maindrive gear bearing retainer depth B.

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  (4) Calculate and select the correct maindrive gear bearing shim thickness.
    Formula: C = B - A
    C :Dimension between the maindrive gear bearing and bore in the front cover
    B: Depth of the maindrive gear bearing bore in the front cover
    A: Maindrive gear bearing height
    • Refer to the maindrive gear bearing shim selective chart.

  Maindrive gear bearing shim selective chart

  Dimension C (mm {in}) | Shim thickness (mm {in})
  --- | ---
  2.75—2.85 {0.1083—0.1122} | 2.7 {0.106}
  2.85—2.95 {0.1122—0.1161} | 2.8 {0.110}
  2.95—3.05 {0.1161—0.1201} | 2.9 {0.114}
  3.05—3.15 {0.1201—0.1240} | 3.0 {0.118}
  3.15—3.25 {0.1240—0.1280} | 3.1 {0.122}
  3.25—3.35 {0.1280—0.1319} | 3.2 {0.126}
  3.35—3.45 {0.1319—0.1358} | 3.3 {0.130}
  3.45—3.55 {0.1358—0.1398} | 3.4 {0.134}
  3.55—3.65 {0.1398—0.1437} | 3.5 {0.138}
  3.65—3.75 {0.1437—0.1476} | 3.6 {0.142}
  3.75—3.85 {0.1476—0.1516} | 3.7 {0.147}
  3.85—3.95 {0.1516—0.1555} | 3.8 {0.150}
  3.95—4.05 {0.1555—0.1594} | 3.9 {0.154}
  4.05—4.15 {0.1594—0.1634} | 4.0 {0.157}
  4.15—4.25 {0.1634—0.1673} | 4.1 {0.161}

    Maindrive gear shaft total end play
    0.05—0.15 mm {0.0020—0.0059 in}

  (5) Using a depth gauge, measure the countershaft front bearing depth D.

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    Note
    • The countershaft bearing is located below the contact surface of the case and front cover.

  (6) Using a depth gauge, measure the countershaft front bearing retainer depth E.

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  (7) Calculate and select the correct countershaft front bearing shim thickness.
    Formula: F = E + D
    F :Dimension between the countershaft front bearing and bore in the front cover
    E: Depth of the countershaft front bearing bore in the front cover
    D: Countershaft front bearing depth
    • Refer to the countershaft front bearing shim selective chart.

  Countershaft front bearing shim selective chart

  Dimension F (mm {in}) | Shim thickness (mm {in})
  --- | ---
  2.45—2.55 {0.0965—0.1004} | 2.3 {0.091}
  2.55—2.65 {0.1004—0.1043} | 2.4 {0.094}
  2.65—2.75 {0.1043—0.1083} | 2.5 {0.098}
  2.75—2.85 {0.1083—0.1122} | 2.6 {0.102}
  2.85—2.95 {0.1122—0.1161} | 2.7 {0.106}
  2.95—3.05 {0.1161—0.1201} | 2.8 {0.110}
  3.05—3.15 {0.1201—0.1240} | 2.9 {0.114}
  3.15—3.25 {0.1240—0.1280} | 3.0 {0.118}
  3.25—3.35 {0.1280—0.1319} | 3.1 {0.122}

    Countershaft total end play
    0.15—0.25 mm {0.0059—0.0098 in}

8. Position the maindrive gear bearing shim, oil baffle, and the countershaft bearing shim onto the front cover.

  Note
  • If necessary, apply a light coat of petroleum jelly to the shims and oil baffle.

9. Apply sealant to the contact surfaces of the transmission case and front cover as shown in the figure.

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10. Install the front cover to the transmission case.

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  Tightening torque:

  19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

  Note
  • To prevent damage to the oil seal lip during assembly, tape maindrive gear shaft splines.