Reassembly
1. Install the oil seal, shift arm, and shift lever in the
transmission housing.
8 x 1.0 mm SPECIAL BOLT
32 N-m (3.2 kg-m, 23 Ib-ft)
SPRING WASHER
SHIFT ARM
TRANSMISSION HOUSING
SHIFT LEVER
OIL SEAL
Replace.
2. Install the shift detent spring and spring set plate.
8 x 1.25 mm SPECIAL BOLT
26 N-m (2.6 kg-m, 19 Ib-ft)
SPRING SET PLATE
SHIFT DETENT SPRING
3. Install the oil seal, select arm, and select lever in
the clutch housing.
8 x 1.0 mm SPECIAL BOLT
32 N-m (3.2 kg-m, 23 Ib-ft)
SPRING WASHER
SELECT ARM
OIL SEAL
Replace.
CLUCH
HOUSING
SELECT LEVER
4. Install the differential assembly into the clutch
housing.
DIFFERENTIAL ASSEMBLY
CLUTCH HOUSING
Transmission
Reassembly
5. Install the spring washer, then insert the mainshaft
and countershaft into the shift forks and install
them as an assembly.
NOTE: Tape the mainshaft splines before instal-
lation.
COUNTERSHAFT
ASSEMBLY
MAINSHAFT
ASSEMBLY
SPRING WASHER
SHIFT FORK
ASSEMBLY
Tape the main-
shaft splines.
6. Install the change holder assembly in the clutch
housing.
NOTE: Place the interlock finger in the groove of
the select arm.
6 x 1.0 mm SPECIAL BOLTS
15 N-m (1.5 kg-m, 11 Ib-ft)
SELECT
ARM
CHANGE HOLDER
ASSEMBLY
INTERLOCK FINGER
7. Lift the mainshaft assembly, then install the
reverse idle gear shaft assembly with the spring pin
matching the groove of the clutch housing.
REVERSE IDLE GEAR
SHAFT ASSEMBLY
SPRING PIN
GROOVE
8. Shift the reverse synchro sleeve to the driven gear
side. Lift the mainshaft assembly and reverse idle
gear shaft assembly, then install the reverse shift
fork assembly.
REVERSE SHIFT FORK
ASSEMBLY
9. Install the reverse shift arm.
6 x 1.0 mm SPECIAL BOLTS
15 N-m (1.5 kg-m, 11 Ib-ft)
REVERSE SHIFT ARM
10. Apply liquid gasket to the surface of the transmis-
sion housing mating with the clutch housing as
shown.
NOTE:
• Use liquid gasket (P/N 08718-0001).
• Remove any dirt or oil from the sealing surface.
• Seal the entire circumference of the bolt holes to
prevent oil leakage.
• If 20 minutes have passed after applying liquid
gasket, reapply it and assemble the housings.
• After assembly, wait at least 30 minutes before
refilling with oil.
11. Install the dowel pins on the clutch housing.
12. Place the transmission housing over the clutch
housing, being careful to line up the shafts.
NOTE: Make sure the 3rd/4th shift fork shaft col-
lar mates with the 3rd/4th shift fork shaft.
3RD/4TH SHIFT FORK SHAFT COLLAR
TRANSMISSION
HOUSING
TRANSMISSION
HOUSING
DOWEL PINS CLUTCH HOUSING
a. Place the shift lever as a shown.
SHIFT LEVER
Neutral
position.
SHIFT ARM
SHIFT PIECE
Transmission
Reassembly
b. Lower the transmission housing, then place the
shift arm in the groove of the shift piece by turn-
ing the shift lever.
TRANSMISSION HOUSING
SHIFT LEVER
SHIFT
ARM
SHIFT PIECE
c. Check the operation of the shift lever.
13. Lower the transmission housing with snap ring
pliers, and set the snap ring in the groove of the
countershaft bearing.
SNAP RING
14. Check that the snap ring is securely seated in the
groove of the countershaft bearing.
Dimension A as installed: 1.60—8.15 mm
(0.063-0.321 in)
COUNTERSHAFT
BEARING
1 5. Tighten the transmission housing attaching bolts in
a crisscross pattern in several steps as shown below.
Torque: 45 N-m (4.5 kg-m, 33 Ib-ft)
16. Install the 36 mm sealing bolt.
NOTE: Apply liquid gasket (P/N 08718-0001) to
the threads.
17. Install the steel balls, springs, and sealing bolts.
NOTE: Apply liquid gasket (P/N 08718-0001) to
the threads, but don’t plug the hole with liquid
gasket.
STEEL BALL
(3/8 in)
14 x 1.0 mm SEALING BOLT
33 N-m (3.3 kg-m, 24 Ib-ft)
SPRING (L. 25 mm)
36 mm SEALING BOLT
35 N-m (3.5 kg-m, 25 Ib-ft)
SPRING
(L. 24.2 mm) 12 x 1.0 mm
SEALING BOLT
22 N-m (2.2 kg-m,
16 Ib-ft)
STEEL BALL
(5/16 in)
16 x 1.0 mm
SEALING
BOLT COMP
42 N-m
(4.2 kg-m, 30 Ib-ft)
18. Install the back-up light switch and neutral position
switch.
NOTE: Apply liquid gasket (P/N 08718-0001) to
the threads.
19. Install the differential speed sensor and vehicle speed
sensor (VSS).
VSS
(O-RING Replace.)
NEUTRAL POSITION
SWITCH
25 N-m (2.5 kg-m,
18 Ib-ft)
DIFFERENTIAL
SPEED SENSOR
BACK-UP LIGHT SWITCH
25 N-m (2.5 kg-m, 18 Ib-ft)
A: 8 x 1.25 mm
24 N-m (2.4 kg-m, 17 Ib-ft)
B: 8 x 1.25 mm
26 N-m (2.6 kg-m, 19 Ib-ft)
C: 6 x 1.0 mm
12 N-m (1.2 kg-m, 9 Ib-ft)