Assembly of Transmission

HINT: Coat all of the sliding and rotating surface with gear oil before assembly.

1. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE




a. Before installing the output shaft, use SST to remove the counter gear center bearing outer race.
SST 09608-35014 (09608-06020, 09608-06090)

HINT: Install the outer race after installing the counter gear.




b. Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.
2. INSTALL INPUT SHAFT AND COUNTER GEAR




a. Apply gear oil to the needle roller bearing.
b. Install the needle roller bearing to the input shaft.




c. Install the input shaft and counter gear together.




d. Using SST and a hammer, install the counter gear center bearing outer race.
SST 09316-60010 (09316-00010)

HINT: Be careful not to damage the bearing rollers.

3. INSTALL BEARING RETAINER




a. Using a snap ring expander, install the bearing snap ring.

HINT: Be sure the snap ring is flush with the intermediate plate surface.




b. Using a torx socket wrench, install and toque the screws.

Torque: 13 N-m (130 kgf-cm, 9 ft-lbf)




4. INSTALL REVERSE GEAR Using SST, install the reverse gear.
SST 09312-20011




5. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a snap ring pliers, install snap ring.




6. INSTALL FIFTH GEAR AND OUTPUT SHAFT REAR BEARING
Using SST, install the 5th gear and rear bearing.
SST 09312-20011 (09313-00010, 09313-00030, 09313-00040, 09313-00050)




7. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.




8. INSTALL NO.3 CLUTCH HUB
Using SST and a hammer, drive in No.3 clutch hub.
SST 09316-60010 (09316-00010, 09316-00070)

HINT: When installing the clutch hub, support the countershaft in front with a 3 - 5 lb hammer or equivalent.




9. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.
10. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING AND COUNTER FIFTH GEAR




a. Install the bearing spacer.
b. Apply gear oil to the needle roller bearings.
c. Assemble the counter 5th gear, synchronizer ring and needle roller bearings.




d. Install the 5th gear assembly with the synchronizer ring slots aligned with the shifting keys.




11. INSTALL SPACER AND BEARING
a. Install the spacer.
b. Install the bearing with the ball shield toward the rear.
c. Using a socket wrench and hammer, drive in the bearing.

HINT: When driving in the bearing, support the countershaft in front with a 3 - 5 lb hammer or equivalent.




12. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a snap ring expander, install the snap ring.




13. INSTALL SPEEDOMETER DRIVE GEAR
a. Put a clip on the output shaft and install the drive gear clip into the slot.
b. Slide the drive gear with clip and fit the clip into the holes.




14. INSPECT COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust clearance.

Standard clearance: 0.10 - 0.41 mm (0.0039 - 0.0161 in.)

15. INSTALL SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
a. Install the reverse idler gear and shaft.
b. Install the No.3 shift fork, No.3 fork shaft and reverse shift arm.




1. Coat the pin with MP grease and insert it into the reverse shift head hole.




2. Install the No.3 shift fork shaft through No.3 shift fork and the reverse shift arm.
3. Align the No.3 shift fork with the No.3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove.lnstall No.3 shift fork shaft to the intermediate plate.
c. Install No.4 shift fork shaft.




1. Push the pin, which was installed into the reverse shift arm hole, into the groove of No.3 shift fork shaft.




2. Install the No.3 shift fork shaft through No.3 shift fork and the reverse shift arm.
3. Align the No.3 shift fork with the No.3 hub sleeve groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove. Install No.3 shift fork shaft to the intermediate plate.




d. Using a pin punch and hammer, drive in the slotted spring pin until it is flush with the fork.




e. Apply MP grease No.3 interlock pin and install the pin into the intermediate plate hole.
f. Install the No.2 shift fork and fork shaft.




1. Apply MP grease to No.2 interlock pin and install the pin into the shaft hole.




2. Place the No.2 shift fork into the groove of No.2 hub sleeve.
3. Install the No.2 fork shaft to the shift fork through the intermediate plate.




g. Install the snap ring to the No.2 fork shaft.




h. Apply MP grease to No.1 interlock pin and install the pin into the intermediate plate.




i. Install the No.1 shift fork and fork shaft.
1. Install the No.1 shift fork into the groove of No.1 hub sleeve.
2. Install the No.1 fork shaft to the shift fork through the intermediate plate.




j. Install the snap ring to the No.1 fork shaft.




k. Install the No.1 and No.2 shift fork set bolts with lock washers.

Torque: 12 N-m (125 kgf-cm, 9 ft-lbf)




l. Using pliers, stake the bolts with lock washers.
16. INSTALL LOCKING BALL AND SPRING




a. Install the balls and spring into each hole.




b. Apply liquid sealer to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Using SST, install and torque the four plugs.
SST 09313-30021

Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)




17. INSTALL REVERSE IDLER GEAR SHAFT STOPPER
Install the reverse idler gear shaft stopper and torque the bolt.

Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)




18. DISMOUNT INTERMEDIATE PLATE FROM VISE
a. Dismount the intermediate plate from the vise.
b. Remove the bolts, nuts, plate washers and gasket.
19. INSTALL TRANSMISSION CASE TO INTERMEDIATE PLATE




a. Remove the any packing material and be careful not to drop oil on the contacting surfaces of transmission case or intermediate plate.
b. Apply seal packing to the transmission case as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent




c. Align the each bearing outer race and each shift fork shaft end with the case holes.
d. Using a plastic hammer, tap on the case to install it.




20. INSTALL BEARING SNAP RINGS
Using a snap ring expander, install the two snap rings.
21. INSTALL FRONT BEARING RETAINER




a. Remove the any packing material and be careful not to drop oil on the contacting surfaces of the front bearing retainer or transmission case.
b. Apply seal packing to the retainer as shown, and install it to the transmission case.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent




c. Apply liquid sealer to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install and torque the bolts.

Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)

22. INSTALL EXTENSION HOUSING




a. Install the shift and select lever into the extension housing.




b. Remove the any packing material and be careful not to drop oil on the contacting surfaces of the extension housing or intermediate plate.
c. Apply seal packing to the extension housing.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent




d. Connect the shift and select lever to the shift fork shaft.




e. Install the shift lever housing to shift and select lever shaft, push in the extension housing.
f. Install and torque the bolt.

Torque: 39 N-m (400 kgf-cm, 29 ft-lbf)




g. Install the nine bolts to the extension housing.
h. Torque the bolts.

Torque: 37 N-m (375 kgf-cm, 27 ft-lbf)

23. AFTER INSTALLING EXTENSION HOUSING, CHECK FOLLOWING ITEMS:
a. Check to see that the input shaft and output shaft rotate smoothly.
b. Check to see that shifting can be made smoothly to all positions.




24. INSTALL RESTRICT PINS
a. Install the restrict pins together with a gasket.

HINT: Install the black pin on the reverse gear/5th gear side.

b. Torque the restrict pins.

Torque: 40 N-m (410 kgf-cm, 30 ft-lbf)




25. INSTALL CLUTCH HOUSING
a. Install the clutch housing.
b. Install and torque the nine bolts.

Torque: 37 N-m (375 kgf-cm, 27 ft-lbf)




26. INSTALL SHIFT LEVER RETAINER
a. Install the shift lever retainer with a oil baffle.
b. Install and torque the six bolts.

Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

27. INSTALL SPEEDOMETER DRIVEN GEAR
a. Install the speedometer driven gear.
b. Install the bolt with lock plate.
c. Torque the bolt.

Torque: 13 N-m (130 kgf-cm, 9 ft-lbf)

28. INSTALL BACK-UP LIGHT SWITCH
a. Install and torque the back-up light switch.

Torque: 40 N-m (410 kgf-cm, 30 ft-lbf)

b. Install the wire clamp.
29. INSTALL REAR SPEED SENSOR (w/ ABS)