M/T Differential Thrust Clearance Adjustment
M/T Differential Thrust Clearance Adjustment
Removal
1. M/T Change Lever Assembly
1. Remove the change lever assembly (A).
2. Remove the 8 x 10 mm dowel pins (B).
2. Back Up Light Switch
1. Remove the back-up light switch (A) and the 18 mm sealing washer (B).
3. M/T Output Shaft Speed Sensor
1. Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).
4. M/T Transmission Housing Assembly
1. Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (C), and the steel balls (D).
2. Remove the 8 mm flange bolts in a crisscross pattern in several steps.
3. Remove the 32 mm sealing cap (A).
4. While expanding the 69 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).
5. Release the snap ring pliers, and remove the transmission housing.
6. Remove the 14 x 20 mm dowel pins (D).
5. M/T Reverse Shift Fork
1. Remove the reverse shift fork (A).
6. Reverse Idler Gear
1. Remove the reverse idler gear (A) and the reverse idler gear shaft (B).
7. Reverse Lock Cam
1. Remove the reverse lock cam (A).
8. M/T Mainshaft and Countershaft and Shift Fork Assembly
1. Apply a thin layer of tape to the mainshaft splines to protect the seal.
NOTE: Do not apply too much tape as it will damage the oil seal.
2. Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).
3. Remove the 26 mm washer (E).
4. Remove the 36 mm spring washer (F).
9. Differential Assembly
1. Remove the differential assembly (A).
2. Remove the magnet (B).
Adjustment
1. M/T Differential Thrust Clearance Adjustment
1. Remove the oil seal (A).
NOTE: Be careful not to damage the transmission housing while removing the oil seal.
2. If you removed the 80 mm shim (A) from the transmission housing, reinstall the same sized shim.
3. Install the differential assembly (A).
4. Install the transmission housing onto the clutch housing.
NOTE: Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
5. Use the 40 mm I.D. driver handle to bottom the differential assembly in the clutch housing.
6. Measure the clearance between 80 mm shim and the bearing outer race in the transmission housing.
7. If the clearance exceeds the standard, select a new 80 mm shim from the following table. If the clearance measured in step 6 is within the standard, go to step 10.
8. Remove the transmission housing.
9. Replace the thrust shim with the correct one selected in step 7, then recheck the clearance.
10. Install a new oil seal flush with the transmission housing using the 65 mm oil seal driver.
Installation
1. Differential Assembly
1. Install the magnet (A).
NOTE: Clean the magnet any time the transmission is disassembled.
2. Install the differential assembly (B).
2. M/T Mainshaft and Countershaft and Shift Fork Assembly
1. Install the 36 mm spring washer (A).
NOTE: Be sure to install the spring washer in the direction shown.
2. Install the 26 mm washer (B).
3. Apply a thin layer of tape to the mainshaft splines (C) to protect the seal.
NOTE: Do not apply too much tape as it will damage the oil seal.
4. Install the mainshaft assembly (D) and the countershaft assembly (E) with the shift fork assembly (F), as an assembly.
3. Reverse Lock Cam
1. Install the reverse lock cam (A).
4. Reverse Idler Gear
1. Install the reverse idler gear (A) and the reverse idler gear shaft (B).
5. M/T Reverse Shift Fork
1. Install the reverse shift fork (A).
6. M/T Transmission Housing Assembly
1. Clean any dirt or oil from the mating surface of the transmission housing and the clutch housing.
2. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
3. Install the 14 x 20 mm dowel pins (A).
4. Set the tapered cone ring pawl (B) faces the 5th shift fork (C).
5. Place the transmission housing on the clutch housing, making sure to line up the shafts.
6. While expanding the 69 mm snap ring (D) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring.
7. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.
NOTE: Install the 32 mm sealing cap (E) after setting in the 69 mm snap ring.
8. Make sure the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.
Dimension (1) as installed: 3.3-6.5 mm (0.130-0.256 in)
9. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the threads of the 32 mm sealing cap. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
10. Install the 8 mm flange bolts finger-tight.
11. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.
12. Install the steel balls, the detent ball springs, and the detent bolts (A) with new 12 mm sealing washers (B).
7. M/T Output Shaft Speed Sensor
1. Install the output shaft (countershaft) speed sensor (A) with a new O-ring (B) and the plain washer (C).
8. Back Up Light Switch
1. Install the back-up light switch (A) with a new 18 mm sealing washer (B).
9. M/T Change Lever Assembly
1. Clean any dirt or oil from the mating surface of the change lever assembly and the transmission housing.
2. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
3. Install the 8 x 10 mm dowel pins (A).
4. Install the change lever assembly (B).