Manual Transmission Reassembly
Manual Transmission Reassembly
NOTE: Prior to reassembly, clean all the parts in solvent, dry them, and apply MTF to any contact surfaces.
1. Install the magnet (A) and differential assembly (B).
NOTE: Clean the magnet any time the transmission is disassembled.
2. Install the 36 mm spring washer (A) and the 26 mm washer (B) over the ball bearing (C). Note the installation direction of the spring washer.
3. Apply vinyl tape to the mainshaft splines (D) to protect the seal. Install the mainshaft and the countershaft (E) with the shift forks (F), as an assembly.
NOTE: Do not apply tape thick to damage the oil seal.
4. Install the reverse idler gear (A) and the reverse gear shaft (B).
5. Install the reverse shift fork (A).
6. Select the proper size 52 x 62 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment M/T Main Shaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M, and the 52 x 62 mm shim into the transmission housing (C).
7. Clean any dirt or oil from the transmission housing sealing surface.
8. 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.
9. Install the two 14 x 20 mm dowel pins (A).
10. Place the transmission housing on the clutch housing, making sure to line up the shafts.
11. While expanding the 69 mm snap ring (B) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in countershaft ball bearing snap ring groove.
NOTE: Install the 32 mm sealing cap (C) after setting in the 69 mm snap ring.
12. Make sure that the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.
13. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, 08718-0009, or 08718-0012) to the threads of the 32 mm sealing cap, and install it on 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.
14. Install the 8 x 1.25 mm flange bolts finger-tight.
15. Torque the 8 x 1.25 mm flange bolts in a crisscross pattern in several steps.
16. Install new washers (A), the drain plug (B), the filler plug (C), a new O-ring (D), and the output shaft (countershaft) speed sensor (E).
17. Install the back-up light switch (A) with a new 18 mm sealing washer (B) and the transmission hanger (C).
18. Clean any dirt or oil from the change lever assembly sealing surface.
19. 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.
- Allow it to cure at least 30 minutes after assembly before filling the transmission with MTF.
20. Install the 8 x 10 mm dowel pins (A) and the change lever assembly (B).
21. Install the steel balls (A), the detent ball springs (B), and the set screws (C) with new 12 mm sealing washers (D).
22. Install the 20 mm bolt (E) with a new 20 mm sealing washer (F).