Transmission Case

1. TRANSMISSION CASE

Tightening torque: N.m (kg-m, ft-lb)
T: 19.6 ± 0.1 (2.00 ± 0.015, 14.5 ± 0.1)





1) Position interlock plungers (5.56 x 19.6), one plunger in hole between 1-2 and 3-4 fork rod holes, and one plunger in hole between 3-4 and reverse fork rod holes.





2) Install reverse shifter lever (1), reverse idler gear (2) and reverse idler gear shaft (3), and secure with straight pin (4).

NOTE: Be sure to install reverse idler shaft from the rear side.

3) Install reverse arm fork spring, ball and interlock plunger (5.56 x 19.6) to reverse fork rod arm (5). Insert reverse fork rod (6) into hole in reverse fork rod arm and hold it with outer snap ring (7) using ST. ST 399411700 ACCENT BALL INSTALLER

CAUTION: Apply grease to plunger to prevent it from falling.

4) Position ball (8) (7.1438), spring (9) and gasket (10) in reverse shifter rod hole, on left side transmission case, and tighten checking ball plug (11).

CAUTION: Replace gasket with a new one.





5) Adjustment of reverse idler gear position
(1) Move reverse shifter rod toward REV side. Adjust clearance between reverse idler gear and transmission case wall, using reverse shifter lever (1).





Clearance A: 6.0 - 7.5 mm (0.236 - 0.295 in)





(2) After installing a suitable reverse shifter lever, shift into neutral. Using a thickness gauge, measure clearance between reverse idler gear and transmission case wall and adjust with washer(s).





Clearance: 0 - 0.5 mm (0 - 0.020 in)





6) Installation of 1-2 shifter fork (12) and rod (13).
(1) Install 1-2 fork rod into 1-2 shifter fork via the hole on the rear of transmission case.
(2) Align the holes in rod and fork, and drive straight pin (6 x 22) into these holes using ST. ST 398791700 STRAIGHT PIN REMOVER

NOTE:
- Set other rods to neutral.
- Make sure interlock plunger (5.56 x 19.6) is on the 3-4 fork rod side.

7) Installation of 3-4 shifter fork (14) and rod (15).
(1) Install interlock plunger (3 x 11.9) onto 3-4 fork rod.

CAUTION: Apply a coat of grease to plunger to prevent it from falling.

(2) Install 3-4 fork rod into 3-4 shifter fork via the hole on the rear of transmission case.
(3) Align the holes in rod and fork, and drive straight pin (6 x 22) into these holes. ST 398791700 STRAIGHT PIN REMOVER

NOTE:
- Set reverse fork rod to neutral.
- Make sure interlock plunger (installed before) is on the reverse fork rod side.

8) Install 5th shifter fork (16) onto the rear of reverse fork rod (6). Align holes in the two parts and drive straight pin into place. ST 398791700 STRAIGHT PIN REMOVER





9) Position balls (17), checking ball springs (18) and gaskets (19) into 3-4 and 1-2 rod holes, and install plugs (20).

CAUTION: Replace gasket with a new one.





10) Installation of speedometer driven gear (21).
(1) Install washer and speedometer shaft, and press fit oil seal with ST. ST 899824100 or 499827000 PRESS

CAUTION: Use new oil seal, if it has been removed.

(2) Install vehicle speed sensor 2.

CAUTION: Use new vehicle speed sensor 2, if it has been removed.

Tightening torque:
5.9 ± 1.5 Nm (60 ± 15 kg-cm, 52 ± 13 in-lb)

(3) Install speedometer driven gear and snap ring.