Installation
Synchro Ring and Gear Inspection
Installation
1. M/T Countershaft
1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2. Install the 1st gear distance collar (A).
3. Install the needle bearing (B).
4. Install 1st gear (C).
5. Install the friction damper (A).
6. Install the synchro ring (B).
7. Install the synchro spring (C).
8. Install the 1st/2nd synchro hub (A) by aligning the friction damper fingers (B) with the grooves in the 1st/2nd synchro hub.
9. Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B).
NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.
10. Install the synchro spring (A).
11. Install the synchro ring (B) by aligning the synchro ring fingers (C) with the 1st/2nd synchro hub grooves (D).
12. Check the operation of the 1st/2nd synchro hub set.
13. Install the friction damper (A) to the 2nd gear distance collar (B).
14. Install the 2nd gear distance collar and the friction damper by aligning the friction damper fingers (C) with the grooves (D) in the 1st/2nd synchro hub.
15. Install the needle bearing (A).
16. Install 2nd gear (B).
17. Support the countershaft (A) on steel block, then press on 3rd gear (B) using the 40 mm I.D. driver handle and a press (C).
NOTE: Do not exceed the maximum pressure.
18. Press on 4th gear (A) using the 40 mm I.D. driver handle and the press (B).
NOTE: Do not exceed the maximum pressure.
19. Press on 5th gear (A) using the 40 mm I.D. driver handle and the press (B).
NOTE: Do not exceed the maximum pressure.
20. Install the distance collar (A).
21. Install the 32 mm shim (B).
22. Temporarily press on the used ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.
23. Measure the clearance between the ball bearing (A) and the 32 mm shim (B) with a feeler gauge (C).
24. If the measured clearance in step 23 is not within the standard, select another suitable 32 mm shim from the table, then go to next step to replace the 32 mm shim and the ball bearing with new ones. If the measured clearance in step 23 is within the standard, go to next step to replace only the ball bearing with a new one.
25. Support the ball bearing (A) on steel blocks (B).
26. Use the press (C) and an attachment (D) to press the countershaft out of the ball bearing.
27. Remove the 32 mm shim.
28. Install the correct 32 mm shim.
NOTE: If necessary, replace the 32 mm shim with the correct one selected in step 24.
29. Press on a new ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press
NOTE: Make sure the ball bearing is installed in the correct direction.
30. Recheck the clearance.
31. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
32. Tighten a new special bolt (B) (left-hand threads).
NOTE: Apply new MTF to the bolt threads and flange.
2. M/T Mainshaft 3rd and 4th Gear
1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2. Install the needle bearing (A).
3. Install 3rd gear (B).
4. Install the synchro ring (C) with the synchro spring (D).
5. Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 3rd/4th synchro hub.
NOTE: Make sure to install the 3rd/4th synchro hub in the direction shown.
6. Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle, the 35 mm I.D. bearing driver attachment and a press.
7. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub.
8. Check the operation of the 3rd/4th synchro hub set.
9. Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 3rd/4th synchro hub.
10. Install 4th gear (E) onto the synchro ring.
3. M/T Mainshaft 5th Gear
1. Install the 4th/5th gear distance collar (A) with the needle bearings (B).
2. Install 5th gear (C).
3. Install the synchro ring (D) with the synchro spring (E) onto 5th gear.
4. Install the 5th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th synchro hub.
5. Press on the 5th synchro hub (A) using the 40 mm I.D. driver handle, the 35 mm I.D. bearing driver attachment and the press.
6. Install the 5th synchro sleeve (A) by aligning the slots of the 5th synchro sleeve and the 5th synchro hub (B).
NOTE: Make sure to align the slots in the 5th synchro hub as shown.
7. Check the operation of the 5th synchro hub set.
8. Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 5th synchro hub.
9. Install the MBS distance collar (E).
10. Install the tapered cone ring (F).
11. Install a new angular ball bearing (G).
12. Press on the angular ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.
4. 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.
5. Reverse Idler Gear
1. Install the reverse idler gear (A) and the reverse idler gear shaft (B).
6. M/T Reverse Shift Fork
1. Install the reverse shift fork (A).
7. 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).
8. 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).
9. Back Up Light Switch
1. Install the back-up light switch (A) with a new 18 mm sealing washer (B).
10. 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).