Assembly (2)

Shift Control Components





1. Install 5th-6th shift fork to 5th-6th coupling sleeve.
2. Install 5th-6th fork rod (reversal side) to 5th-6th shift fork.
3. Drive retaining pin into 5th-6th shift fork using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





4. Install 5th-6th fork rod to adapter plate.
5. Install 5th-6th fork rod bracket to 5th-6th fork rod.
6. Drive retaining pin into 5th-6th fork rod bracket using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





7. Install 5th-6th control lever to adapter plate, and then tighten mounting bolts to the specified torque.

CAUTION: Set the projection upward.





8. Insert check balls into adapter plate.





9. Install reverse shift fork onto reverse coupling sleeve.
10. Insert reverse fork rod to reverse shift fork.
11. Drive retaining pin into reverse shift fork using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





12. Insert interlock pin and interlock plunger into adapter plate.





13. Install 1 et-2nd shift fork onto 1 et-2nd coupling sleeve.
14. Insert 1st-2nd fork rod to 1st-2nd shift fork.
15. Drive retaining pin into 1st-2nd shift fork using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





16. Install 3rd-4th shift fork onto 3rd-4th coupling sleeve.
17. Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
18. Drive retaining pin into 3rd-4th shift fork (reversal side) using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





19. Insert interlock pin and check balls into adapter plate.





20. Install 3rd-4th fork rod to adapter plate.
21. Install 3rd-4th fork rod bracket to 3rd-4th fork rod.
22. Drive retaining pin into 3rd-4th fork rod bracket using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





23. Insert check ball, check ball spring into adapter plate, apply genuine anaerobic liquid gasket or equivalent to check ball plug threads, and tighten to the specified torque
24. Install shifter cap to 3rd-4th control lever.





25. Insert 3rd-4th control lever to adapter plate, and then tighten mounting bolts to the specified torque.

CAUTION: Make sure the top and bottom are oriented correctly.





26. Insert check ball spring and check ball into the adapter plate, apply genuine anaerobic liquid gasket or equivalent to the check ball plug threads, and tighten to the specified torque.





27. Install striking rod to adapter plate.
28. Install striking lever to striking rod.
29. Drive retaining pin into striking lever using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





30. Install baffle plate onto adapter plate, and tighten mounting bolts to the specified torque.

Case Components





1. Install counter front bearing in transmission case.
2. Install oil gutter to transmission case.





3. Apply genuine anaerobic liquid gasket or equivalent to adapter plate mounting surface of transmission case as shown in the figure.

CAUTION: Completely remove all moisture and oil, etc., from the transmission case and adapter plate mounting surfaces.

4. Install magnet to adapter plate.





5. Install adapter plate onto transmission case and then tap adapter plate with a soft hammer to seat it completely on transmission case.





6. Install snap ring to main drive gear bearing using snap ring pliers.

CAUTION: Do not reuse snap ring.





7. Tighten baffle plate mounting nut to the specified torque.





8. Apply multi-purpose grease to the lip of front cover oil seal. Install front cover oil seal approximately 8.55 - 9.55 mm (0.336 - 0.376 inch) above from the front cover edge surface using a drift.
Tool number : KV38102100 (J25803-01)

CAUTION:
^ Do not reuse front cover oil seal.
^ When installing, do not tilt front cover oil seal.





9. Install front cover gasket and front cover to transmission case.

CAUTION: Do not reuse gasket.

10. Temporarily tighten bolts in the positions shown in the figure.





11. Install remaining bolts, and tighten them by hand.

CAUTION: Four bolts pointed by arrows in the figure are not reusable.





12. Tighten bolts to the specified torque in order as shown in the figure.





13. Install washer to withdrawal lever ball pin, and install it to front cover.Tighten withdrawal lever ball pin to the specified torque.
14. Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque.
15. Install reverse idler shaft, reverse idler needle bearing, reverse idler gear and reverse thrust washer to nor rift





16. Apply multi -purpose grease to the lip of control shaft oil seal. Install control shaft oil seal to rear extension using the drift.
Tool number : ST35291000 ( - )

CAUTION:
^ Do not reuse striking rod oil seal.
^ When installing, do not tilt striking rod seal.





17. Apply multi - purpose grease to the lip of the rear oil seal. Using a drift, to install rear oil seal. 1.2 - 2.2 mm (0.047 - 0.087 inch) above from the rear extension edge surface.
Tool number : ST33400001 (J26082)

CAUTION:
^ Do not reuse rear oil seal.
^ When installing, do not tilt rear oil seal.

18. Place shift forks in neutral position.





19. Apply genuine anaerobic liquid gasket or equivalent to rear extension mounting surface of adapter plate as shown in the figure.

CAUTION: Completely remove all moisture, oil, etc., from the adapter plate and rear extension mating surfaces.





20. Install rear extension to transmission case, and tighten mounting bolts to the specified torque in order as shown in the figure.
21. Install control lever housing to rear extension, and then tighten mounting bolts to the specified torque.








22. Insert return spring and plunger into the rear extension, apply genuine anaerobic liquid gasket or equivalent to the return spring plug threads, and then tighten to the specified torque.

CAUTION: The right and left return springs and plungers are different, so make sure they are installed correctly.





23. Install shift check pin and control bracket as a one unit to rear extension, and then tighten mounting bolts to specified torque.
24. After screwing plunger, neutral position switch and back-up lamp switch to rear extension with 1-2 pitches, apply genuine anaerobic liquid gasket or equivalent to the switch threads, and tighten them to the specified torque.





25. Drive retaining pin into control rod using a pin punch [6 mm (0.24 inch) dia.].

CAUTION: Do not reuse retaining pin.





26. Insert check select spring and check ball into rear extension.





27. Install rear extension upper cover gasket and rear extension upper cover to rear extension.

CAUTION:
^ Do not reuse rear extension upper cover gasket.
^ Avoid tangling check select spring.

28. Tighten rear extension upper cover bolts to specified torque in order as shown in the figure.