- Install the differential gear assembly.
- Install the output shaft assembly.
- Install the input shaft assembly.
- Install 1st/2nd shift arm (A) to the synchroniser sleeve and insert the shift rod (B) into the reverse lever fulcrum bracket. Align the hole in the arm with the rod and install a new double spring pin (C).
NOTE:
Before installing the 3rd/4th shift arm, make sure that the interlock pin is inserted to the 3rd/4th shift rod.
- Install the 3rd/4th shift arm (D) to the sleeve. Install the shift rod (E) to the collar of the reverse lever fulcrum bracket. Align the rod and arm holes. Install a new roll pin (F).
- Install the reverse shift lever.
- Before installing the 5th and reverse shift rods, make sure that the interlock pin is inserted to the 5th shift rod.
NOTE:
- Install the 5th and reverse shift rods at the same time. The rods must be facing the same direction as the detent groove.
- Mesh the reverse rod and the reverse shift lever.
- Install reverse idler shaft together with the reverse idler gear into the clutch housing.
Make sure reverse lever engages the gear collar.
- Install the reverse detent plug, reverse detent spring and reverse detent ball.
Torque:
25 Nm (2.5 kgf/m, 18 lbf/ft)
- Install the rear output shaft bearing outer race and output shaft bearing shims into the transmission case.
- Install the differential side bearing outer race and differential side bearing shims into the transmission case.
- Install the transmission case.
NOTE:
Carefully wipe any oil and other foreign material from the mating surfaces of the clutch housing and transmission case. Apply liquid gasket (LOCTITE No. 518 or equivalent) to the mating surface of clutch housing. Then tighten fourteen bolts in diagonal sequence to the specified torque.
NOTE:
If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings. Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.
- The heads of the bolts to be tightened at the same time as the transmission hanger are painted green. Take care to install the bolts to their proper position.
Torque:
38 Nm (3.8 kgf/m, 28 lbf/ft)
