Part 3

Viscous Coupling Side





a. Place side gear and thrust washer on pinion mate gears installed on differential case.
b. Measure dimension X.
- Measure dimension X in at least four places.
a. Set tool on viscous coupling and lock gauging cylinder in place with set screw.





b. Install gauging plunger into cylinder.





c. Install pinion mate gears and side gears with original washers on differential cases.

Align paint marks.
d. Tighten differential case bolts.
e. Set tool and allow plunger to rest on side gear thrust washer.
f. Measure gap between plunger and cylinder.
This measurement should give exact clearance between side gear and differential case with washers.

Standard clearance:
0.1 - 0.2 mm (0.004 - 0.008 inch)

g. If not within specification, adjust clearance by changing thickness of side gear thrust washer.





Side gear thrust washers for viscous coupling side:
Refer to image.





4. Install viscous coupling.





5. Install speedometer drive gear on differential case.
- Align the projection of speedometer drive gear with the groove of differential case.





6. Press differential side bearings on differential case.





7. Install final gear and tighten fixing bolts in a crisscross pattern.

SHIFT CONTROL COMPONENTS
INSPECTION





Check contact surface and sliding surface for wear, scratches, projections or other damage.





CASE COMPONENTS
REMOVAL AND INSTALLATION
Input Shaft Oil Seal





- Apply multi-purpose grease to seal lip of oil seal before installing.





Mainshaft front bearing outer race
- Extract the oil channel and remove the mainshaft front bearing outer race.

ADJUSTMENT
INPUT SHAFT END PLAY AND DIFFERENTIAL SIDE BEARING PRELOAD
If any of the following parts are replaced, adjust input shaft end play.
- Input shaft
- Input shaft bearing
- Clutch housing
- Transmission case

If any of the following parts are replaced, adjust differential side bearing preload.
- Differential case
- Differential side bearing
- Clutch housing
- Transmission case





1. Remove differential side bearing outer race (transmission case side) and shim(s).





2. Reinstall differential side bearing outer race without shim(s).
3. Install input shaft and final drive assembly on clutch housing.
4. Install transmission case without input shaft bearing shim(s).
Then tighten it to the specified torque.





Refer to image.





5. Using the following procedures, measure clearance between bearings and transmission case.

- Differential side
a. Attach dial indicator. If clamp diameter of dial indicator is too small or too large, attach dial indicator using a magnetic stand.





b. Insert Tool all the way into differential side gear. Move Tool up and down and measure dial indicator deflection.





- Input shaft side
a. Set dial indicator on end of input shaft.
b. Move input shaft up and down and measure dial indicator deflection.








6. Select shims with proper thickness with table as a guide. Refer to image.
7. Install selected differential side bearing adjusting shim and differential side bearing outer race.





8. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.





- Tighten transmission case fixing bolts to the specified torque. Refer to image.





c. Measure turning torque of final drive assembly.

Turning torque of final drive assembly (New bearing):
4.9 - 7.8 Nm (50 - 80 kg-cm, 43 - 69 inch lbs.)

- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.

MAINSHAFT BEARING PRELOAD
If any of the following parts are replaced, adjust mainshaft bearing preload.
- Mainshaft
- Mainshaft bearings
- Clutch housing
- Transmission case





1. Remove mainshaft rear bearing outer race and shim(s).





2. Reinstall mainshaft rear bearing outer race without shims.
3. Clean mating surfaces of clutch housing and transmission case with solvent.
4. Install mainshaft and mainshaft front bearing outer race into transmission case. Turn mainshaft while holding bearing outer race so that bearings are properly seated.





5. Place Tools (bridge and gauging cylinder) onto machine -face of transmission case. Allow gauging cylinder to rest on surface of mainshaft front bearing outer race. Use proper screw in bridge to lock gauging cylinder in place.





6. Turn bridge over and place Tool (gauging plunger) into gauging cylinder.





7. Place bridge, legs up, onto machined surface of clutch housing. Allow gauging plunger to rest upon mating surface where mainshaft front bearing outer race fits.









8. Measure with feeler gauge distance between gauging cylinder and shoulder of gauging plunger.
9. Use feeler gauge reading to select correct mainshaft preload shim(s).





Mainshaft bearing adjusting shim: Refer to image.

10. Install selected mainshaft bearing adjusting shim and mainshaft bearing outer race.
11. Check total turning torque after assembly.

ASSEMBLY





1. Install striking lever and striking rod.





2. Install selector and retaining pin.





3. Install reverse gate assembly.
- Be careful not to lose check ball.





4. Install final drive assembly.
5. Install input shaft and mainshaft with 1st & 2nd shift fork assembly.
- Be careful not to damage input shaft oil seal.





6. Install interlock balls and plunger.





7. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th fork rod, stopper ring and retaining pin.





8. Install interlock balls.





9. Install 5th shift fork, then install fork rod, stopper ring and retaining pin.





10. Install 5th & reverse check plug, spring and ball.





- Apply sealant to bolt threads. Refer to image.





11. Install reverse lock spring on 5th & reverse bracket.
- Pay attention to its direction.





12. Install check ball and reverse lever spring on reverse lever assembly.
- Apply multi-purpose grease to check ball.
- Pay attention to direction of reverse lever spring.





13. Install reverse lever assembly on clutch housing.





14. Install reverse arm shaft and retaining pin.





15. Hook reverse lock spring and reverse lever spring on reverse lever assembly.





16. Mesh 4th gear, then install reverse idler gear and shaft.
- Pay attention to direction of tapped hole.





17. Place magnet on clutch housing.





18. It bearing preload of mainshaft was adjusted, install selected shim(s) into transmission case.
- To aid in installation of transmission case, place shift selector in the 1st and 2nd shift bracket or between 1st and 2nd bracket and 3rd and 4th bracket.





19. Apply sealant to mating surface of transmission case and install it. Refer to image.
20. Install position switch.





21. Apply sealant to threads of check plugs.





Install balls, springs and plugs. Refer to image.
22. After assembly, check that you can shift into each gear smoothly.





23. Measure total turning torque.

Total turning torque (New bearing):
8.8 - 21.6 Nm (90 - 220 kg-cm, 78 - 191 inch lbs.)

- When old bearing is used again, preload will be slightly less than the above. Make sure torque is close to the specified range.