Assembly
Precaution1. All O-rings and gasket must be replaced with the new ones included in the overhaul kit.
2. Before assembly, make sure all parts are completely clean.
3. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil.
Clutch hub
CAUTION: Align the synchronizer ring grooves with the clutch hub keys during installation.
NOTE:
- The synchronizer rings all have the same basic shape. Carefully note these distinguishing features:
a. 5th and Reverse synchronizer rings are the smallest.
b. Reverse has 2 notches in the teeth.
c. 4th and 3rd are the next larger and are exactly the same.
d. 2nd and 1st are the biggest and are exactly the same.
- Press each clutch hub assembly onto the mainshaft in the proper direction.
- Install the clutch hubs with the chamfers of the inner gear teeth as shown.
Extension Housing Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Oil seal
1. Apply transmission oil to outer periphery.
2. Install a new oil seal with the SST.
Rod cover
1. Apply transmission oil to rubbers on the rod cover.
2. Install the rod cover with the mark facing forward.
Roll pin
CAUTION: Install the roll pin with the seam facing as shown in the figure.
Install a new roll pin into the control lever end.
Select-lock spindle, spring, and spring cap
1. Install the select-lock spindle, spring, and spring cap.
Tightening torque: 7.8 - 11 N-m (80 - 110 cm-kg, 69 - 95 in-lb)
NOTE: If the select-lock spindle is not pushed down, the ball will not correctly engage the select-lock spindle.
2. Push the select-lock spindle down by pushing on the control rod.
Bearing Housing Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Countershaft center bearing
Press the countershaft center bearing into the bearing housing with a suitable pipe.
Adjustment shim
Measure the clearance between the countershaft center bearing and the bearing housing.
If not within specification, adjust the clearance by installing the correct adjustment shim(s).
Standard clearance: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim: 0.1 mm (0.004 in), 0.3 mm (0.012 in)
Mainshaft front bearing
Press the mainshaft front bearing into the bearing housing with a suitable pipe.
Adjustment shim
Measure the clearance between the mainshaft front bearing and the bearing housing.
If not within specification, adjust the clearance by installing the correct adjustment shim(s).
Standard clearance: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim: 0.1 mm (0.004 in), 0.15 mm (0.006 in), 0.3 mm (0.012 in)
Reverse idler gear shaft
Press the reverse idler gear into the bearing housing.
Tightening torque: 7.8 - 11 N-m (80 - 110 cm-kg, 69 - 95 in)
Adjustment washer
Measure the clearance between the adjustment washer and snap ring.
If not within specification, adjust the clearance by installing the correct adjustment washer.
Maximum clearance: 0.1 mm (0.004 in)
Adjustment washer: 2.6 mm (0.102 in), 2.8 mm (0.110 in), 3.0 mm (0.118 in)
Mainshaft Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Clutch hub assembly
1. Set the 2nd gear and the 1st/2nd clutch hub assembly on the mainshaft, then press in the mainshaft.
2. Set the 3rd gear and 3rd/4th clutch hub assembly on the mainshaft, then press on the 3rd/4th clutch hub assembly with the SST.
3. Install a new snap ring on the front of the mainshaft.
4. Install the inner race, needle bearing, and 1st gear.
Mainshaft and Countershaft Parts
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer key spring
5. Synchronizer ring (4th)
6. Needle bearing
7. Main drive gear
8. Bearing housing assembly
9. Washer
10. Mainshaft gear assembly
11. Countershaft
12. Counter reverse gear
13. Washer
14. Inner race
15. Needle bearing
16. Reverse gear
17. Synchronizer ring (Reverse)
18. Clutch hub assembly
19. Locknut (Mainshaft)
20. Synchronizer ring (5th)
21. 5th gear
22. Steel ball
23. Thrust lock washer
24. C-washer
25. Retaining ring
26. Mainshaft rear bearing
27. C-washer
28. Retaining ring
29. Washer
30. Snap ring
31. Spacer
32. Counter 5th gear
33. Countershaft rear bearing
34. Locknut (Countershaft)
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Mainshaft and countershaft
1. Place the mainshaft gear assembly and the countershaft on the bearing housing.
2. Use a suitable bar to press in the countershaft
Locknut (Mainshaft)
NOTE: Use pads in the vise to prevent damaging the bearing housing.
1. Secure the bearing housing in a vise.
2. Slide the clutch hub sleeves onto 1st and reverse gears to lock the mainshaft.
3. Tighten a new locknut with the SST.
Tightening torque: 128 - 235 N-m (13 - 24 m-kg, 94 - 174 ft-lb)
4. Use a chisel to stake the locknut.
Thrust lock washer
1. Insert the steel ball and the thrust lock washer for 5th gear.
CAUTION:
- Use only 3.0 mm (0.118 in) C-washers, otherwise; it may not be possible to install the rear C-washers.
- The two C-washers must be the same thickness, or bearing failure will result.
2. Install the C-washers and hold them with the retaining ring.
3. Measure the clearance between the thrust lock washer and C-washers (5th gear end play).
If the end play is not within specification, adjust the clearance by installing the correct thrust lock washer.
Standard play: 0.1 - 0.3 mm (0.004 - 0.012 in)
Thrust lock washer thickness: 6.2 mm (0.244 in), 6.4 mm (0.252 in), 6.5 mm (0.256 in), 6.6 mm (0.260 in)
Mainshaft rear bearing
1. Drive on the mainshaft rear bearing with the SST. Install the C-washers, retaining ring, and washer. Secure them with a new snap ring.
CAUTION: Verify there is no clearance between the mainshaft rear bearing and the C-washers.
2. Measure the clearance between the C-washers and washer. If end play is not within specification, adjust the clearance by installing the proper C-washers.
Standard play: 0 - 0.1 mm (0 - 0.004 in)
C-washer thickness: 2.9 mm (0.114 in), 3.0 mm (0.118 in), 3.1 mm (0.122 in), 3.2 mm (0.126 in)
Countershaft rear bearing
Drive the countershaft rear bearing onto the countershaft with the SST.
Locknut (Countershaft)
1. Shift the clutch hub sleeves to 1st gear and reverse gear to put the gears in a double-engaged condition.
NOTE: Use pads in the vise to prevent damaging the SST.
2. Connect the SST to the mainshaft and tighten it securely in a vise.
3. Tighten a new locknut.
Tightening torque: 128 - 196 N-m (13 - 20 m-kg, 94 - 145 ft-lb)
4. Use a chisel to stake the locknut.
Shift Fork and Shift Rod Parts
Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Spring and ball
NOTE: There are 2 types of springs; be sure to install them correctly.
1. Insert the spring and ball (5th/Reverse) into the bearing housing.
2. Press the spring and ball (5th/Reverse) with a screwdriver and the SST to install the shift rod.
Shift fork and rod
Install the 5th/Reverse shift fork and 5th/Reverse shift rod into the bearing housing.
Interlock pin
1. Position the interlock pin into the bearing housing with the SST.
2. Verify that the interlock pin is correctly installed.
Shift fork and rod, interlock pin
1. Set the 1st/2nd shift fork onto the 1st/2nd clutch hub assembly.
2. Install the 3rd/4th shift fork and 3rd/4th shift rod, and install the interlock pin into the bearing housing as in Step 4.
Roll pin
CAUTION: Install the roll pin with the seam facing as shown in the figure.
Install a new roll pin into each shift fork.
Spring, spacer, clip
1. Slide the spring and spacer onto the 5th/Reverse shift rod. While pressing the spacer, install a new clip.
2. Install new clips to the 3rd/4th shift rod and 1st/2nd shift rod.
3. Verify that the centers of the shift fork and clutch hub sleeve are aligned properly.
If they are not, select the proper washer for between 1st gear and the mainshaft front bearing, and between reverse gear and the mainshaft front bearing.
CAUTION: The total thickness of the front and rear washers should be 5.9 - 6.0 mm (0.2323 - 0.2362 in).
4. The following washer thicknesses are available.
Intermediate housing
1. Apply sealant to the contacting surfaces of the intermediate housing and bearing housing.
2. Mount the intermediate housing to the bearing housing by tapping it lightly with a plastic hammer.
Roll pin
CAUTION: Install the roll pin with the seam facing forward.
Install a new roll pin into each shift rod end.
Housing Components
1. Oil seal
2. Snap ring
3. Steel ball
4. Speedometer drive gear
5. Snap ring
6. Transmission case
7. Extension housing
8. Main drive gear bearing
9. Snap ring
10. Countershaft front bearing
11. Snap ring
12. Adjustment shim
13. Gasket
14. Front cover
15. Speedometer driven gear
16. Neutral switch
17. Back-up light switch
18. Boot
19. Release fork
20. Release bearing
1. Assemble in the order shown in the figure, referring to Assembly Note.
2. Check the gearshift lever operation.
Assembly note
Oil seal
1. Apply transmission oil to outer periphery.
2. Install a new oil seal with the SST.
Extension housing
1. Apply sealant to the contact surfaces of the bearing housing and transmission case.
2. Align the inner shift lever and shift rod end groove, and install the extension housing.
3. Apply sealant to the bolt threads, and install the bolts.
Tightening torque: 16 - 23 N-m (1.6 - 2.3 m-kg, 12 - 17 ft-lb)
Main drive gear bearing
Drive on the main drive gear bearing with the SST, and secure it with a new snap ring.
Countershaft front bearing
Drive on the countershaft front bearing with the SST, and secure it with a new snap ring.
Adjustment shim
After measuring dimensions (A) and (B) shown in the figure, use an adjustment shim(s), as specified below, of the thickness corresponding to the value of (A) minus (B), so that bearing end play will be within specification.
Bearing end play: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim thickness: 0.10 mm (0.004 in), 0.15 mm (0.006 in), 0.30 mm (0.012 in)
Release fork
1. Apply More white TA No.2 or equivalent organic molybdenum grease to the shaded areas of the release bearing and release fork.
2. Install the release bearing and release fork.