Part 2

REAR COVER/REVERSE IDLER GEAR
Disassembly/Inspection/Reassembly

NOTE:
- Inspect the needle bearings for galling and rough movement.
- Coat all parts with ATF before reassembly.

MAINSHAFT
Disassembly/Inspection/Reassembly

NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

MAINSHAFT
Mainshaft 3rd Gear Removal

1. Remove mainshaft 3rd gear, 4th gear, and thrust washer (43 x 74 mm) from the mainshaft using the special tool and a press as shown.

Inspection

NOTE:
- Inspect the 43 x 74 mm thrust washer when disassembling the mainshaft assembly or replacing mainshaft 3rd gear and/or 1st/4th clutch assembly.
- Lubricate all parts with ATF during assembly.

1. Install mainshaft 3rd gear on the mainshaft using the special tool and a press as shown.

2. Assemble the thrust needle bearing, needle bearing, and 4th gear, and install the 43 x 74 mm thrust washer using the special tool and a press as shown.

NOTE: Replace the 43 x 74 mm thrust washer, if it can be installed by pressing with your hand.

3. Spin mainshaft 4th gear by hand to check for clearance. The clearance is normal if it turns freely without binding.
4. Remove the mainshaft bearing from the transmission housing.

5. Assemble the parts below on the mainshaft.

NOTE: Do not assemble the O-rings and mainshaft 1st gear.

6. Torque the mainshaft locknut to 29 Nm (3.0 kgfm, 22 ft. lbs.).

7. Move the 1st/4th clutch assembly to check the axial clearances.

8. Measure the clearance between the 1st/4th clutch guide and 1st gear collar with a feeler gauge.

STANDARD: 0 - 0.08 mm (0 - 0.003 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

9. If the clearance is out of tolerance, remove the 43 x 74 mm thrust washer, and measure the thickness.

NOTE: If the 0.08 mm (0.003 inch) feeler gauge can be inserted, perform this step.

10. Select and install a new 43 x 74 mm thrust washer, then recheck.
11. After replacing the 43x 74 mm thrust washer, make sure that the clearance is within the tolerance.

SEALING RINGS
Sub-Assembly

NOTE:
- Lubricate all parts with ATF during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Assemble the mainshaft sub-assembly when assembling the transmission.

1. Assemble the parts below on the mainshaft.

Replacement
The sealing rings (37 mm and 42 mm) are synthetic resin with chamfered ends. Check conditions of the sealing rings. Replace the sealing rings only if worn, distorted or damaged.

NOTE: Apply all parts with ATF during assembly.

1. Squeeze the sealing ring together slightly before installing for better fit.
2. Install new sealing rings on the mainshaft.

3. After installing the sealing rings verify the following:
The sealing rings are fully seated in the groove. The sealing rings are not twisted. The chamfered ends of the sealing ring are properly joined.

COUNTERSHAFT

Disassembly/Inspection/Reassembly

NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings. 9 Locknut has left-hand threads.

INSPECTION
Clearance Measurements

NOTE: Lubricate all parts with ATF during assembly.

1. Assemble the parts below on the countershaft.

NOTE: Do not install the O-rings during inspection.

2. Torque the countershaft locknut to 29 Nm (3.0 kgfm, 22 1 ft. lbs.).

NOTE: Countershaft locknut has left-hand threads.

3. Hold the 1st-hold clutch assembly against the parking gear. Measure the clearance between the 1sthold clutch distance collar and the 1st-hold clutch with a feeler gauge.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

4. If the clearance is out of tolerance, remove the 1st hold clutch distance collar and measure its length.
5. Select and install a new 1st-hold clutch distance collar, then recheck.

6. After replacing the 1st-hold clutch distance collar, make sure that the clearance is within tolerance.

7. Attach a dial indicator to the side of the 2nd gear.

8. Measure 2nd gear axial clearance while pushing the 1st gear towards the reverse clutch assembly.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

STANDARD: 0.05 - 0.13 mm (0.002 - 0.005 inch)

9. If the clearance is out of tolerance, remove the 45.5 x 60 mm thrust washer, and measure its thickness.
10. Select and install a new 45.5 x 60 mm thrust washer, then recheck.

11. After replacing the 45.5 x 60 mm thrust washer, make sure that the clearance is within tolerance.

Sub-Assembly

NOTE:
- Lubricate all parts with ATF during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Assemble the countershaft sub-assembly when assembling the transmission.

1. Assemble the parts below on the countershaft.

COUNTERSHAFT 2ND GEAR ASSEMBLY
Ball Bearing Replacement

NOTE: Lubricate all parts with ATF during assembly.

1. Remove the one-way clutch hub and ball bearing from the countershaft 2nd gear using the special tool and a press as shown.

2. Install a new ball bearing and the one-way clutch hub on the countershaft 2nd gear using the special tool and a press as shown.

2ND GEAR ONE-WAY CLUTCH
Disassembly/Inspection/Reassembly

1. Separate countershaft 2nd gear from the parking gear by turning the parking gear in the direction shown.

2. Remove the one-way clutch by prying it up with the end of a screwdriver.

3. Inspect the parts as follows:

4. After the parts are assembled, hold countershaft 2nd gear and turn the parking gear in the direction shown to be sure it turns freely. Also make sure the parking gear does not turn in the opposite direction.

1ST GEAR ONE-WAY CLUTCH
Disassembly/Inspection/Reassembly
1. Remove the set plate from countershaft 1st gear.

2. Remove the one-way clutch by prying it up with the end of a screwdriver.

3. Inspect the parts as follows:
4. Assemble the one-way clutch, thrust needle bearing and set plate on the countershaft 1st gear.

5. Hold countershaft 1st gear, and turn the countershaft 2nd gear assembly in the direction shown to be sure it turns freely. Also make sure the countershaft 2nd gear assembly does not turn in the opposite direction.

CLUTCH

Illustrated Index -'96 Model

Illustrated Index -'97 -'98 Models

Disassembly

1. Remove the snap ring, then remove the clutch end plate, clutch discs and plates.
2. Remove the disc spring, if it is not staked.

NOTE: The 3rd and 4th clutches on '97 model do not have disc spring.

'96 MODEL: 2ND, 3RD, 4TH and 1ST-HOLD CLUTCHES
'97 -'98 MODELS: 1ST-HOLD CLUTCH

'96 MODEL: REVERSE and 1ST CLUTCHES
'97 - '98 MODELS: 1ST, 2ND and REVERSE CLUTCHES

3. Install the special tools as shown.

NOTE: For 2nd, 3rd, 1st-hold and reverse clutches.

NOTE: For 1st and 4th clutches.

CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.

4. Compress the return spring with the special tool.

5. Remove the snap ring. Then remove the special tools, spring retainer and return spring.

6. Wrap a shop rag around the clutch drum, and apply air pressure to the oil passage to remove the piston. Place a finger tip on the other end while applying air pressure.

Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Lubricate all parts with ATF before assembly.

1. Inspect the check valve; if it's loose, replace the piston.
2. Be sure that the 1st clutch piston disc spring is securely staked.

NOTE: Some of the 1st clutch disc springs are not staked. If the disc spring is not staked, install it in step 10.

3. Install new O-rings on the piston.

4. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.

NOTE: Lubricate the piston O-ring with ATF before installing.

CAUTION: Do not pinch the O-ring by installing the piston with too much force.

5. Install the return spring and spring retainer, and position the snap ring on the retainer.

6. Install the special tools as shown.

NOTE: For 2nd, 3rd, 11st-hold and reverse clutches

NOTE: For 1st and 4th clutches

7. Compress the return spring with the special tool.

8. Install the snap ring.
9. Remove the special tools.
10. Install the disc spring in the direction shown.

NOTE: The 3rd and 4th Clutches on '97 model do not the disc springs.

'96 MODEL: 2ND, 3RD, 4TH and 1ST-HOLD CLUTCHES
'97 -'98 MODELS: 1ST-HOLD CLUTCH

'96 MODEL: REVERSE and 1ST CLUTCHES

NOTE: Install the 1st clutch disc spring if it was removed from the 1st clutch piston.

'97 - '98 MODELS: 1ST, 2ND and REVERSE CLUTCHES
11. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.

12. Starting with a clutch plate, alternately install the clutch plates and clutch discs. Install the clutch end plate with the flat side toward the disc.

NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt and other foreign matter.

13. Install the snap ring.

14. Measure the clearance between the clutch end plate and top disc with a dial indicator.
Zero the dial indicator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.

NOTE: Measure at three locations.

15. If the clearance is not within the service limits, select a new clutch end plate from the following table.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.