Reassembly

1. Install the differential assembly in the clutch housing.





2. Install the shift fork, then drive in the spring pin through the shift piece.

NOTE: Tape the mainshaft spline before installation.

3. Install the spring washer with the angle against the clutch housing as shown.





4. Insert the mainshaft and countershaft into the shift forks and install them as an assembly.





5. Install the reverse idler gear and idler gear shaft in the clutch housing.






6. Install the reverse shift fork in the clutch housing with the 5th/reverse shift piece pin positioned in the slot of the reverse shift fork.

NOTE:
- Check that the steel ball is in the proper position.
- Select the mainshaft thrust shim according to the measurements.





7. Install the oil guide plate and mainshaft thrust shim into the transmission housing.
8. Install the oil gutter plate in the transmission housing.

NOTE: Bend the hook of the oil gutter plate into the hole on the transmission housing.





9. Install the 28 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718-0001 OE) to the thread.

10. Apply liquid gasket to the transmission mating surface of the clutch housing.

NOTE: This transmission uses no gaskets between the major housings; use liquid gasket (P/N 08718-0001 OE). Assemble the housings within 20 minutes after applying the liquid gasket and allow it to cure for at least 30 minutes after assembly before filling it with oil.





11. Install the 14 x 20 mm dowel pins.





12. Set the stopper ring as shown. Place the transmission housing over the clutch housing, being careful to line up the shafts.

NOTE: Set the long arm of 5th shift fork with the hook of stopper ring.

13. Install the snap ring to the countershaft ball bearing.





14. Install the 32 mm sealing bolt.

NOTE: Apply liquid gasket (P/N 08718-0001 OE) to the thread.





15. Torque the bolts in the sequence shown.

8 mm bolts: 28 N-m (2.8 kg-m, 20 lb-ft)
10 mm bolts: 45 N-m (4.5 kg-m, 33 lb-ft)

16. Install the reverse idler shaft bolt.





17. Install the steel balls, springs, washers and setting screws.
18. Install the shift arm assembly.