5TH/6TH GEAR AND HOUSING PARTS ASSEMBLY [TYPE B]

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1. Assemble in the order indicated in the table.

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1 | Clutch housing (See Clutch Housing Assembly Note.)
2 | Control rod
3 | Control end
4 | 1st/2nd shift fork
5 | Control lever
6 | Interlock lever
7 | 3rd/4th shift fork
8 | Inner shift lever
9 | Spring pin
10 | Push pin component and spring
11 | Differential component
12 | Secondary shaft gear component (See Secondary Shaft Gear Component, Primary Shaft Gear Component and Shift Fork and Shift Rod Component Assembly Note.)
13 | Primary shaft gear component (See Secondary Shaft Gear Component, Primary Shaft Gear Component and Shift Fork and Shift Rod Component Assembly Note.)
14 | Shift fork and shift rod component (See Secondary Shaft Gear Component, Primary Shaft Gear Component and Shift Fork and Shift Rod Component Assembly Note.)
15 | Reverse idler gear component (See Reverse Idler Gear Component, Reverse Shift Fork and 5th/Reverse Shift Rod End Assembly Note.)
16 | Reverse shift fork (See Reverse Idler Gear Component, Reverse Shift Fork and 5th/Reverse Shift Rod End Assembly Note.)
17 | 5th/reverse shift rod end (See Reverse Idler Gear Component, Reverse Shift Fork and 5th/Reverse Shift Rod End Assembly Note.)
18 | 5th/reverse shift rod
19 | Magnet
20 | Crank lever component (See Crank Lever Component and Crank Lever Shaft Assembly Note.)
21 | O-ring
22 | Crank lever shaft (See Crank Lever Component and Crank Lever Shaft Assembly Note.)
23 | Pin
24 | Transaxle case component (See Transaxle Case Component Assembly Note.)
25 | Neutral switch
26 | Push pin component
27 | Spring
28 | Bolt and washer
29 | Back-up light switch
30 | Lock bolt
31 | Guide bolt
32 | Lock bolt
33 | Clutch hub (See Clutch Hub and Clutch Hub Sleeve Assembly Note.)
34 | Clutch hub sleeve (See Clutch Hub and Clutch Hub Sleeve Assembly Note.)
35 | Secondary 5th gear (See Secondary 5th Gear Assembly Note.)
36 | Spacer
37 | Gear sleeve
38 | 5th gear
39 | 5th synchronizer ring
40 | Synchronizer key spring
41 | 5th/6th clutch hub component (See 5th/6th Clutch Hub Component and 5th/6th Shift Fork Assembly Note.)
42 | 5th/6th shift fork (See 5th/6th Clutch Hub Component and 5th/6th Shift Fork Assembly Note.)
43 | Secondary 6th gear (See Secondary 6th Gear Assembly Note.)
44 | Synchronizer key spring
45 | 6th synchronizer ring (See 6th Synchronizer Ring Assembly Note.)
46 | 6th gear
47 | Gear sleeve
48 | Bearing (secondary shaft) (See Bearing and Locknut Assembly Note.)
49 | Bearing (primary shaft) (See Bearing and Locknut Assembly Note.)
50 | Locknut (secondary shaft) (See Bearing and Locknut Assembly Note.)
51 | Locknut (primary shaft) (See Bearing and Locknut Assembly Note.)
52 | Rear cover

Clutch Housing Assembly Note

1. Assemble the SST.

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2. Assemble the clutch housing on the SST.

Secondary Shaft Gear Component, Primary Shaft Gear Component and Shift Fork and Shift Rod Component Assembly Note

1. Install the shift fork and shift rod component, primary shaft gear component and secondary shaft gear component at the same time.

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2. Press the control rod end edge to the back of the scraper and press the push pin component into the inner shift lever.

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3. Assemble the shift rod to the clutch housing by tapping the shift rod with a plastic hammer.

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4. Pull out the scraper.

5. Rotate the control end so that the push pin component is positioned at the center of the control end.

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Reverse Idler Gear Component, Reverse Shift Fork and 5th/Reverse Shift Rod End Assembly Note

1. Shift the 3rd/4th shift fork to 4th.

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2. Place the reverse idle gear component to the position shown in the figure.

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3. Assemble the reverse shift fork to the reverse idle gear component, and point the reverse idle gear component thread hole outward.

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4. After assembling the reverse shift fork, verify that the interlock sleeve end and control lever end are aligned as shown in the figure, and the reverse shift fork is engaged with interlock sleeve.

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5. Point the 5th/reverse shift rod end bolt hole and projection outward as shown in the figure, and place the 5th/reverse shift rod end on the reverse shift fork through the 3rd/4th shift fork.

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6. Assemble the 5th/reverse shift rod and tighten the bolts.

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  Tightening torque

  11.8—15.7 N·m {1.2—1.6 kgf·m, 8.7—11.5 ft·lbf}

Crank Lever Component and Crank Lever Shaft Assembly Note

1. Assemble the crank lever component to the change arm and control end.

2. Apply the specified oil to a new O-ring and install the O-ring to the crank lever shaft.

3. Assemble the crank lever shaft to the crank lever component.

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4. Using a flathead screwdriver, rotate the crank lever shaft so that the pin holes of the clutch housing and crank lever shaft are aligned, and then install a new spring pin.

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Transaxle Case Component Assembly Note

1. Apply a thin coat of sealant (TB1216 or TB1216B) to the contact surfaces of the clutch housing and transaxle case, and tighten the transaxle case installation bolts to the specified torque.

  Tightening torque

  37.3—52.0 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}

2. Install the SST through the drive shaft and joint shaft hole.

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Clutch Hub and Clutch Hub Sleeve Assembly Note

1. Align the teeth of the clutch hub sleeve with the clutch hub grooves as shown in the figure, and assemble the clutch hub to the clutch hub sleeve.

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Secondary 5th Gear Assembly Note

1. Install the secondary 5th gear as shown in the figure.

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5th/6th Clutch Hub Component and 5th/6th Shift Fork Assembly Note

1. Install the 5th/6th clutch hub component and the 5th/6th shift fork together.

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2. Align the teeth of the clutch hub sleeve with the 5th synchronizer ring grooves as shown in the figure, and assemble the clutch hub component.

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Secondary 6th Gear Assembly Note

1. Install the secondary 6th gear as shown in the figure.

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6th Synchronizer Ring Assembly Note

1. Align the teeth of the clutch hub sleeve with the 6th synchronizer ring grooves as shown in the figure, and assemble the 6th synchronizer ring.

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Bearing and Locknut Assembly Note

1. Shift to 1st gear.

2. Install the bearing.

3. Lock the primary shaft using the SST.

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4. Tighten the new lock nuts with the bearing onto the primary and secondary shafts.

  Tightening torque

  150—212 N·m {15.3—21.6 kgf·m, 111—156 ft·lbf}

5. Stake the locknuts.

6. Measure the 5th gear thrust clearance using a feeler gauge.

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  • If it exceeds the maximum specification, inspect the contact surfaces of 5th gear and the clutch hub. Replace worn or damaged parts.

  5th gear thrust clearance

  Standard: 0.100—0.220 mm {0.0040—0.0086 in}
  Maximum: 0.270 mm {0.0106 in}

7. Measure the 6th gear thrust clearance using a dial indicator.

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  • If it exceeds the maximum specification, inspect the contact surfaces of 6th gear and the clutch hub. Replace worn or damaged parts.

  6th gear thrust clearance

  Standard: 0.100—0.220 mm {0.0040—0.0086 in}
  Maximum: 0.270 mm {0.0106 in}