Transmission Case: Installation

Install the oil receiver pipe.
CAUTION: Check that the tip of the oil receiver pipe is not lifted or disconnected.

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Temporarily install the reverse idler gear shaft.
NOTE: Perform this step only if the reverse idler gear has not been removed.
1. Remove the bolts and gasket. (Clutch housing side)
2. Temporarily install the reverse idler gear shaft securing bolts using a new gasket. (Clutch housing side)
  CAUTION: Always use a new bolt.
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Install the transmission case.

Apply liquid gasket to the mating surface of the transmission case as shown in the figure.

NOTE:

Before applying liquid gasket, degrease the old liquid gasket seal surface of the transmission case and clutch housing.
Install within 10 min. after applying liquid gasket.

Preparation items:

Liquid gasket: THREE BOND 1281 or equivalent

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Tighten the transmission case and the clamp (A).
CAUTION: Always use a new bolt.

Tightening torque:

29 N.m (3.0 kgf-m, 21.4 ft-lb)

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Install the reverse idler gear shaft securing bolts using a new gasket. (Transmission case side)
CAUTION: Always use a new bolt.

Tightening torque:

28 N.m (2.9 kgf-m, 20.7 ft-lb)

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Tighten the reverse idler gear shaft securing bolt. (Clutch housing side)
Tightening torque:

28 N.m (2.9 kgf-m, 20.7 ft-lb)

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Install a new snap ring.

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Install the rear bearing retainer.
CAUTION: Always use a new bolt.

Tightening torque:

30 N.m (3.1 kgf-m, 22.1 ft-lb)

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Install the shift arm pivot.

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Using a new spring pin, install the gear shift head No. 2.
Spring pin insertion depth (from the end face of the gear shift head No. 2):

0 mm (0 in)

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Install the ball.

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Install the 6th gear bearing inner race.
NOTE: Apply transmission gear oil to the 6th gear bearing inner race.

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Install the needle roller bearing.
NOTE: Apply transmission gear oil to the needle roller bearing.

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Install the 6th gear.
NOTE: Apply transmission gear oil to the 6th gear.

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Install the synchronizer ring No. 2.
NOTE: Apply transmission gear oil to the synchronizer ring No. 2.

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Use the ST to install the clutch hub No. 4, hub sleeve No. 4, gear shift fork No. 4, and gear shift fork rod No. 4 as a unit.
CAUTION: Align the key groove (a) of the clutch hub No. 4 with the protrusion (b) of the synchronizer ring No. 2.

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Preparation tool:

ST: INSTALLER (18682AA000)

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Install the snap ring.

Select a suitable snap ring so that the clearance between the clutch hub No. 4 and snap ring is within the specified value.

NOTE:

Select the thickest one that can be installed.
The snap ring is a non-reusable part.

Specification:

0 - 0.1 mm (0 - 0.004 in)

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Install the selected snap ring.

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Install the balls, compression spring, and head straight screw plug.

CAUTION: Always use a new head straight screw plug.

Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)

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(A)	Ball
(B)	Compression spring
(C)	Head straight screw plug

Using a new E-ring, install the shift arm.
NOTE: Align the end of the shift arm with the cutout portion of the gear shift fork rod No. 4.

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Install the gear shift fork rod No. 5.

Set the balls (A), and install the gear shift fork rod No. 5 (B).

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Install the balls, compression spring, and head straight screw plug.

CAUTION: Always use a new head straight screw plug.

Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)

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(A)	Head straight screw plug
(B)	Compression spring
(C)	Ball

Install the bolt that secures the gear shift fork rod No. 5.
CAUTION: Always use a new bolt.

Tightening torque:

19.5 N.m (2.0 kgf-m, 14.4 ft-lb)

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Using a new spring pin, install the gear shift head No. 1.
Spring pin insertion depth (from the end face of the gear shift head No. 1):

0 mm (0 in)

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Using a new spring pin, install the gear shift head No. 3.
Spring pin insertion depth (from the end face of the gear shift head No. 3):

0 mm (0 in)

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Install the shift shaft and shift block.

Install the shift block.

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Set the shift shaft and shift block as a unit, and then slide the shift block to install it.

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Install the extension case. Ref. to MANUAL TRANSMISSION>EXTENSION CASE>INSTALLATION .