Case: Service and Repair

NOTE: The front and rear oil seals do not need to be removed unless you are replacing them.





DISASSEMBLY
- Disassemble in the order indicated in the illustration, referring to the following notes:





Extension Housing (12)
^ Turn the extension housing to remove it.





Transmission Case (13)
^ Remove the transmission case from the intermediate housing and gear component by using the Special Service Tool (SST).








ASSEMBLY
1. Assemble in the order indicated in the illustration, referring to the following notes:

Oil Seal (1)
1. Apply transmission oil to the outer periphery.





2. Install a new oil seal with the SST.





Extension Housing (7)
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. Tighten to 18 - 26 Nm (14 - 19 ft. lbs.).





Main Drive Gear Bearing (8)
^ Install the main drive gear bearing by using the SST, and secure it with a new snap ring.





Countershaft Front Bearing (10)
^ Install the countershaft front bearing by using the SST, and secure it with a new snap ring.








Adjustment Shim (12)
^ After measuring dimensions A and B shown in the illustration, use the adjustment shim(s) of the thickness corresponding to the value of A minus B, so that bearing end play will be within 0 - 0.1 mm (0 - 0.004 inch). Adjustment shim thickness are 0.10 mm (0.004 inch), 0.15 mm (0.006 inch), or 0.30 mm (0.012 inch).





Clutch Release Fork And Clutch Release Collar (20)
1. Apply Mori White TA No.2 or equivalent organic molybdenum grease to the shaded areas of the clutch release collar and release fork.
2. Install the clutch release collar and clutch release fork.

2. Check the gearshift lever operation.