Assembly
ASSEMBLYPrecaution
1. All 0-rings and gasket must be replaced with the new ones included in the overhaul kit.
2 Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transmission with transmission oil.
. After assembly, shift the transmission to each position, and check that the smooth and correct operation.
Assembly procedure
Caution: Align the synchronizer ring grooves with the clutch hub keys during installation.
Note:
(a) Press each clutch hub assembly onto the mainshaft in the proper direction.
(b) Install the clutch hubs with the chamfers of the inner gear teeth as shown.
1. Place the 3rd gear and synchronizer ring on the mainshaft.
2. Press on the clutch hub assembly (3rd/4th) by using a suitable pipe and the SST.
Caution: In pressing on the assembly, be sure to align the synchronizer ring and clutch hub (3rd/4th) grooves.
3. Insert the snap ring by using snap ring pliers.
4. After mounting the 2nd gear and synchronizer ring on the mainshaft, use a suitable piece of pipe to press on the clutch hub assembly (1st/2nd).
Caution: Same as the caution for Step 2.
5. After installing the synchronizer ring, inner race, needle bearing, 1st gear, and washer to the mainshaft, install the needle bearing, synchronizer ring, and main drive gear.
. Press the ball bearing and roller bearing into the bearing housing along with adjustment shims using a suitable piece of pipe.
7. Measure the clearance between the ball bearing and the bearing housing. If the clearance is not within the standard, adjust it by using an adjustment shim(s).
Standard clearance: -O.05-O.O5mm {-O.002-O.002 in}
Variation: 0 ±O.O5mm {O 0.002 in}
Adjustment shim: O.1mm {O.004 in), O.3mm {O.012 in}
8. Install the bearing cover to the bearing housing.
Tightening torque Bearing cover: 16-22 N.m {1.6-2.3 kgf.m, 12-16 ft.lbf}
Shaft bracket (black bolts): 37-53 N.m 13.7-5.5 kgf.m, 27-39 ft.lbf}
9. (1) Place the spacer on the roller bearing.
Note: Replace spacer and bearing as a set.
(2) Place the mainshaft and main drive gear assembly and the counter gear.
(3) Use a suitable round bar to press in the countershaft.
10. (1) Secure the reverse idle gear and 2 washers to the reverse idle gear shaft.
Tightening torque: 7.9-10.7 N.m {80-110 kgf.cm, 70-95 in.lbf}
(2) Install the counter reverse gear, washer, inner race, needle bearing, reverse gear, and clutch hub assembly (5th/reverse).
11. Secure the bearing housing in a vise installed the pads.
12. Slide the clutch hub sleeves onto 1st and reverse gears to lock the mainshaft.
13. (1) Install the clutch hub assembly (5th/reverse), and tighten a new locknut with the SST.
Tightening torque: 128-206 N.m {13-21 kgf.m, 95-151 ft.lbf}
(2) Use a chisel to crimp the locknut.
14. (1) Install the 5th gear and the synchronizer ring to the mainshaft.
(2) Install the spacer and counter gear.
(3) Install the locknut and fully tighten it by hand.
15. (1) Insert the ball and the thrust lock washer for 5th gear.
(2) Install only the two 3.O mm {O.118 in} thick C-washers in the front mainshaft groove.
Caution: If the C-washers are not pushed fully forward the 5th gear side, the measurement will be incorrect.
16. While pushing the C-washers toward the 5th gear side, measure the clearance between the thrust lock washer and C-washers. If the clearance is not as specified select the proper thrust lock washer.
Standard play: O.1-O.3mm {O.OO4 - 0.011 in}
Thrust lock washer thickness:
6.4mm {O.252 in}, 6.5mm {0.256 in}
6.6mm {O.260 in), 6.7mm {0.264 in}
17. Install the retaining ring.
18. Drive on the mainshaft rear bearing by using the SST, fully seating it against the front C-washers.
19. Install the original C-washers and hold them with the retaining ring.
20. Install the washer and new snap ring.
Caution:
(a) If the points A through D as shown in figure, are not pressed together tightly, the measurement will be incorrect.
(b) If the C-washers will not fit into the rear mainshaft groove, select the proper thickness C-washers.
(c) Ensure both C-washers at this position are the same thickness.
21. With points A through D pressed tightly together, measure the clearance between the washers and snap ring. If the clearance is not as specified, select the proper C-washers.
Standard play: 0.1mm {O.004 ml or less
C washer thickness:
2.9mm {O.114 in}, 3.OEM {O.118 in},
3.1mm {O.122 in}, 3.2mm {O.126 in}
22. Drive on the ball bearing to the countershaft with the SST.
23. Shift the clutch hub sleeves to first gear and reverse gear to put the gears in a double-engaged condition.
24. (1) Install the SST on the mainshaft, and place them securely in a vise.
(2) Tighten the countershaft rear bearing new locknut.
Tightening torque: 118-156 N.m {12-16 kgf.m, 86.8-115 ft.lbf}
(3) Use a chisel to crimp the locknut.
25. Insert the spring and ball (5th/reverse) into the bearing housing.
Note: There are 2 types of springs; be sure to install them correctly.
26. Press the spring and ball (5th/reverse) with the SST and a flat-tipped screwdriver to install the shift rod.
27. Install the shift fork and rod (5th/reverse) to the bearing housing.
28. Position the interlock pin into the bearing housing with the SST.
29. Check to be sure that the interlock pin fits correctly.
30. Install the shift fork and rod (3rd/4th), and install the interlock pin into the bearing housing the same way as in Step 28.
31. Install the shift fork and rod (1st/2nd), the springs, balls, and caps.
32. Install the new roll pins into each shift fork.
Caution: The roll pin should be installed so that the groove of the pin faces as shown in the figure.
33. Check to be sure that the centers of the shift fork and clutch hub sleeve are aligned properly. If they are not, select the proper thrust washer for between 1st gear and the mainshaft bearing, and reverse gear and the mainshaft bearing.
Caution: The total thicknesses of both front and rear thrust washers should be 5.9mm {0.2323 in} or 6.O mm {0.2362 in}.
34. Coat the intermediate housing contact surfaces attached to the bearing housing with sealant.
35. Mount the intermediate housing to the bearing housing by tapping it lightly with a plastic hammer.
36. Install the shift rod end on each shift rod.
Caution: The roll pin should be installed so that the groove of the pin faces toward the front.
37. Mount the ball and speedometer drive gear; then secure them with the new snap ring.
38. Coat the contact surfaces of the extension housing and intermediate housing with sealant.
39. While turning the control rod end to the left, mount the extension housing.
40. Coat the surfaces of the transmission case and bearing housing.
41. Mount the transmission case, and tighten the bolts.
Tightening torque: 18-26 N.m {1.8-2.7 kgf.m, 14-19 ft.lbf}
42. Apply sealant to the control case edges.
43. Install the control case to the center housing.
Tightening torque: 18-26 N.m {1.8-2.7 kgf.m, 14-19 ft.lbf)
44. Install the ball bearing (main drive gear) with the SST, and secure it with the new snap ring.
Caution: At this time, the synchronizer ring groove of the main drive gear should be aligned with the synchronizer key.
45. Install the ball bearing (countershaft) with the SST, and secure it with the new snap ring.
46. After measuring dimensions (A) and (B) shown in the figure, use an adjustment shim(s), as specified below, of the thickness corresponding to the value of (A minus (B), so that bearing end play will be within the standard value.
Bearing end play: O-O.1mm {0-O.004 in}
Adjustment shim thickness:
O.15mm {O.OO6 in}
O.3Omm (O.012 in)
47. Install the gasket and front cover.
Tightening torque: 18-26 N.m {1.8-2.7 kgf.m, 14-19 ft.lbf}
48. Install the control case and the gearshift lever.
49. Check the gearshift lever operation.
50. Apply a coat of molybdenum disulfide grease to the parts of the release bearing and release fork indicated by the shaded lines in the figure.
51. Install the release bearing and release fork.