With FS5W71C & F4W71C Transmission

Gear Components




1. Install bearings into case components.




2. Assemble adapter plate parts.
- Install oil gutter on adapter plate and expand on rear side.




- Install bearing retainer.
a. Insert reverse shaft, then install bearing retainer.




b. Tighten each screw, then stake it at two points.




3. Install main drive gear bearing.
a. Press in main drive gear bearing.
b. Install main drive gear spacer.







c. Select proper main drive gear snap ring to minimize clearance of groove.

Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 in)

d. Install selected snap ring on main drive gear.

Main Drive Gear Snap Ring:

4. Assemble synchronizers.




5. Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft.




6. Assemble 1st main gear, steel ball, and thrust washer on mainshaft.
Before installing steel ball and thrust washer, apply grease to them.
7. Install counter rear bearing to adapter plate.




8. Press mainshaft assembly to adapter plate with Tool.




9. Press counter gear into adapter plate with Tool.




10. Install 3rd main gear and 3rd & 4th synchronizer assembly.
Pay attention to direction of synchronizer.




11. Install thrust washer on mainshaft and secure it with mainshaft front snap ring.
Select proper snap ring that will minimize clearance of groove in mainshaft.
Check mainshaft front snap ring.
12. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.




13. Press counter drive gear with main drive gear with Tool.




Pay attention to direction of counter drive gear.

Counter Drive Gear Snap Ring:

14. Install sub-gear components.
a. Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring that will minimize clearance of groove in counter gear.

Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 in)

b. Remove snap ring, sub-gear bracket and sub-gear from counter gear.
c. Reinstall sub-gear and sub-gear bracket with sub-gear spring between them.




15. Install selected counter drive gear snap ring.




16. Press counter gear front bearing onto counter gear.




17. Assemble parts at rear of adapter plate as follows:

- FS5W71C -
a. Install reverse idler gear to reverse idler shaft with spacers, snap rings and needle bearing.




b. Install insert retainer and O.D. synchronizer to mainshaft.
Pay attention to direction of hub.




c. Install O.D. gear bushing with Tool.
d. Install O.D. main gear and needle bearing.
e. Install spacer, reverse counter gear and O.D. counter gear.
O.D. main gear and O.D. counter gear should be handled as a matched set.
f. Install washer, roller bearing, steel roller, thrust washer, steel ball and speedometer drive gear.
g. Tighten mainshaft rock nut temporarily.
Always use new lock nut.




h. Install countershaft rear end bearing with Tool.

- F4W71C -
a. Install reverse main gear, plain washer and mainshaft nut. Then tighten mainshaft nut temporarily.
Always use new lock nut.

Counter Reverse Gear Snap Rings:

b. Install counter reverse gear and secure with snap ring that will minimize clearance of groove in countershaft.
c. Install reverse idler gear.




18. Mesh 2nd and reverse gears and tighten mainshaft lock nut with Tool.




Use the left chart when deciding the reading torque
(Length of torque wrench vs. setting or reading torque)




19. Tighten countershaft lock nut. (FS5W71C)
Always use new lock nut.
20. Stake mainshaft lock nut and countershaft lock nut with a punch.
21. Measure gear end play.

Shift Control Components




1. Install shift rods, interlock plunger, interlock balls and check balls.




a. 1st-2nd shift fork




b. 3rd-4th shift fork




c. O.D.-reverse shift fork or reverse shift fork

- FS5W71C -

- F4W71C -




2. Install O.D.-rev. fork shaft by rotating O.D.-rev. bracket clockwise (4WD model with mainshaft braking mechanism only).




3. Install E-ring on O.D.-rev. fork rod (4WD model only).




4. Install lever bracket securing bolt (4WD model only).

Case Components




1. Install front cover oil seal.
Apply multi-purpose grease to seal lip.




2. Apply sealant to mating surface of transmission case.




3. Slide gear assembly onto adapter plate by lightly tapping with a soft hammer.




4. Apply sealant to mating surface of adapter plate.




5. Install rear extension.
6. Fit main drive bearing snap ring.







7. Select counter front bearing shim.




8. Install gasket and front cover.
9. Install return spring plugs, check ball, return springs and select check plunger.
10. Install control housing and gasket.