Reassembly

1. Install differential assembly in clutch housing




2. Install mainshaft, countershaft, first/second gear shift shaft and third/fourth gear shift shaft together as an assembly. Make sure forks are in fourth and second gear positions to make installation easier.




3. Lift mainshaft as shown and install interlock into the selector arm.
4. Place shift rod in neutral.




5. Hook interlock into selector arm, first/second gearshift shaft and third/fourth gearshift shaft. Hook shift guide into shift arm.




6. Install fifth/reverse shift shaft and hook its pin into reverse shift fork slot.




7. Install shift guide shaft so it bottoms securely in clutch housing hole. End of shaft should extend no more than 12 mm (0.5 in.) above interlock as shown.
If not, check installation.




8. Install mainshaft bearing retainer plate.




9. Install reverse idler gear and shaft.




10. Install back-up light switch with new washer.
11. Place new gasket on clutch housing.
12. Install dowel pins.




13. Shift transmission into third gear to position shift guide shaft for reassembly. Install transmission housing being careful to line up shafts. Shift guide shaft must seat in blind hole in transmission housing. Do not force installation of housing.




14. Torque 8 x 1.25 mm bolts in sequence shown, to 28 N-m (2.8 kg-m, 21 lb-ft).




15. Install three detent balls, washers, and retaining screws.




16. Install countershaft fifth gear with high side facing down. Then install spring washer with dished surface facing fifth gear.
17. Install spacer collar and needle bearing on the mainshaft.




18. Install mainshaft fifth gear.




19. Install synchronizer ring, synchronizer spring, synchronizer hub and synchronizer sleeve on the mainshaft.




20. Install fifth shift fork into synchronizer sleeve.
21. Install spring washer with dished (concave) surface facing synchronizer hub.




22. Drive spring pin into fifth gear shift fork.
23. Install mainshaft holder 07923-6890101 to prevent shaft from rotating, then shift transmission into reverse gear.




24. Torque mainshaft and countershaft locknuts. Tighten to specified torque, then loosen and retighten to same torque.
90 N-m (9.0 kg-m, 65 lb-ft) 0 90 N-m (9.0 kg-m, 65 lb-ft)

CAUTION: The mainshaft locknut has left-hand threads.




25. Stake shoulders on locknuts into slots in mainshaft and countershaft.
26. Install end cover on transmission housing with new gasket.




27. Torque 6 x 1.0 mm bolts in sequence shown to 12 N-m (1.2 kg-m, 9 lb-ft).