Manual Transmission Reassembly
Manual Transmission Reassembly
NOTE:
- Prior to reassembling, clean all the parts in solvent, dry them, and apply MTF to any contact surfaces.
- Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.
1. Install the magnet (A) and the differential assembly (B).
NOTE: Clean the magnet anytime the transmission is disassembled.
2. Install the 36 mm spring washer (A) and the 26 mm washer (B) over the ball bearing (C).
NOTE: Install the spring washer in the direction shown.
3. Apply tape on the mainshaft (D) spline to protect the seal. Install the mainshaft assembly and the countershaft assembly (E) with the shift fork assembly (F), as an assembly.
4. Install the reverse idler gear (A) and the reverse idler gear shaft (B).
5. Install the reverse shift fork (A).
6. Select the proper size 52 x 62 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. M/T Mainshaft Thrust Clearance Adjustment Install the oil gutter plate (B), oil guide plate M, and the 52 x 62 mm shim into the transmission housing (C).
7. Clean any dirt and oil from the mating surface of the transmission housing and the clutch housing.
8. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the mating surface of the transmission housing and the clutch housing. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
9. Install the two 14 x 20 mm dowel pins (A).
10. Set the tapered cone ring pawl (B) faces the 5th shift fork (C). Place the transmission housing over the clutch housing, making sure to line up the shafts.
11. While expanding the 69 mm snap ring (D) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring.
Release the pliers, and push down the housing until it bottoms and the snap ring snaps in place in the countershaft ball bearing snap ring groove.
NOTE: Install the 32 mm sealing cap (E) after setting in the 69 mm snap ring.
12. Make sure the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.
13. Apply liquid gasket, P/N 08718-0001, evenly to the threads of the 32 mm searing cap.
Install the component within 5 minutes of applying the liquid gasket.
NOTE:
- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
14. Install the 8 mm flange bolts finger-tight.
15. Torque the 8 mm flange bolts in a crisscross pattern in several steps.
16. Clean any dirt or oil from the mating surface of the change lever assembly and the transmission housing.
17. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009 evenly to the mating surface of the change lever assembly and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.
NOTE:
- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
- Allow it to cure at least 30 minutes after assembly before filling the transmission with MTF.
18. Install the 8 x 10 mm dowel pins (A) and the change lever assembly (B).
19. Install the drain plug (A) with new sealing washer (B), and the output shaft (countershaft) speed sensor (C) with new O-ring (D). Install the filler plug (E) with a new sealing washer (F) finger-tight.
20. Install the steel balls, the springs, and the detent bolts (A) with new washers (B).
21. Install the 20 mm bolt (C) and new 20 mm washer (D).
22. Install the back-up light switch (A) with new 18 mm washer (B), and the transmission hanger (C).
23. Install the air cleaner housing bracket (A) and the harness bracket (B).
