Reverse Lever Assembly

DISASSEMBLY

1. Remove case components in accordance with procedure in the Service Manual.

2. Mesh 4th gear, and then remove reverse idler shaft and reverse idler gear.



3. Pull out retaining pin from clutch housing.



4. Remove reverse arm shaft by rotating the shaft while pushing with a suitable tool.



5. Remove reverse lever assembly.
NOTE: be careful not to loose check ball.



6. Remove 5th and Reverse check plug, spring and ball.



7. Remove stopper rings and retaining pins from 5th & Reverse and 3rd & 4th fork rods. When removing stopper rings, use snap ring remover and installer (J34305).

8. Remove 5th & Reverse and 3rd & 4th fork rods. Then remove forks and brackets.



9. Remove both input and mainshafts with 1st & 2nd fork and fork rod as a set.



ASSEMBLY

1. Install input shaft and mainshaft with 1st & 2nd shift fork assembly. Be careful not to damage input shaft oil seal.



2. Install interlock balls and plunger.






3. Install 3rd & 4th shift fork and bracket, then install 3rd & 4th shift rod, stopper ring and retaining pin. When installing stopper ring, use snap ring remover and installer (J34305).



4. Install interlock balls.



5. Install 5th shift fork and bracket, then install shift rod, stopper ring and retaining ring. When installing stopper ring, use snap ring remover and installer (J34305).
NOTE: make sure detents on 5th shift rod face same direction as 1st, 2nd, 3rd, and 4th shift rods.



6. Install 5th & reverse check plug, spring and ball.



7. Install reverse lock spring on 5th & reverse bracket.
^ Pay attention to its direction.



8. Install check ball and reverse lever spring on reverse lever assembly.
^ Apply multi-purpose grease to check ball.
^ Pay attention to direction of reverse lever spring.



9. Install reverse lever assembly on clutch housing.



10. Install reverse arm shaft and retaining pin.



11. Hook reverse lock spring on reverse lever assembly by positioning hooked end of spring into slot, then bending top portion of spring under spring retaining pin.



12. Mesh 4th gear, then install reverse idler gear and shaft.
^ Pay attention to direction of tapped hole.