Shift Fork: Service and Repair

DISASSEMBLY
1. Disassemble in the order indicated in the illustration, referring to the following note:





Clip (19)
2. Remove the clip, spacer, and spring from the 5th/ Reverse shift rod.

ASSEMBLY
- Assemble in the reverse order of disassembly indicated in the illustration, referring to the following notes:





Spring And Ball (23)
1. Insert the spring and ball (5th/reverse) into the bearing housing.





2. Press down the spring and ball (5th/reverse) by using the SST and a screwdriver, and install the shift rod.





5th/Reverse Shift Fork And Rod (21, 22)
^ Install the 5th/reverse shift fork and 5th/reverse shift rod into the bearing housing.





Interlock Pin (18)
1. Position the interlock pin into the bearing housing by using the SSTs.





2. Verify that the interlock pin is correctly installed.

1st/2nd And 3rd/4th Shift Fork And Rod, Interlock Pin (12, 14, 16, 17)
1. Set the 1st/2nd shift fork onto the 1st/2nd clutch hub component.





2. Install the 3rd/4th shift fork and 3rd/4th shift rod, and install the interlock pin into the bearing housing as described in the interlock pin assembly note.





Spring, Clip (9, 10)
1. Slide the spring onto the 5th/Reverse shift rod. While pressing the spring, 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 to install between 1st gear and the mainshaft front bearing, and between reverse gear and the mainshaft front bearing.

4. The following washer thicknesses are available. The total thickness of the front and rear washers should be following. Total thickness is 5.9 - 6.0 mm (0.232 - 0.236 inch). Washer thickness are 2.2 mm (0.087 inch), 2.7 mm (0.106 inch), 3.0 mm ( 0.118 inch), 3.2 mm (0.126 inch), 3.7 mm (0.146 inch).





Spring, Clip (5)
1. Apply sealant to the contact 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.