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M/T Assembly Reassembly

NOTE: Prior to reassembly, clean all the parts in solvent, dry them, and apply MTF to any contact surfaces.
  1. Install the magnet (A) and differential assembly (B).

  1. Install the 8 mm spring washer (A) and the 8 mm special bolt (B).
  1. Install the 36 mm spring washer (C) and 26 mm washer (D) over the ball bearing (E). Note the installation direction of the spring washer.
  1. Tape the mainshaft splines (F) with vinyl tape to protect the seal. Install the mainshaft and countershaft (G) into the shift forks (H), and install them as an assembly.

  1. Install the reverse lock cam.

  1. Install the reverse shift fork.

  1. Install the reverse idler gear (A) and reverse gear shaft (B).

  1. Select the proper size 72 mm shim (A) according to the measurements made during the Mainshaft Thrust Clearance Adjustment. Install the oil gutter plate (B), oil guide plate M (C) and 72 mm shim into the transmission housing (D).

  1. Clean any dirt or oil from the transmission housing and clutch housing mating surface. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the sealing surface as shown.
    NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the old residue and reapply the liquid gasket.

  1. Install the 14 x 20 mm dowel pins (A).
  1. Make the finger (B) of tapered cone ring touch the 5th shift fork (C) as shown.
  1. Lower the transmission housing the rest of the way as you expand the 52 mm snap ring (D). Release the snap ring so it seats in the groove of the countershaft bearing.
  1. Check that the 52 mm snap ring is securely seated in the groove of the countershaft bearing.
    Dimension (1) as installed:
    4.6−8.3 mm (0.18−0.33 in.)

  1. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the threads of the 32 mm sealing screw (E), and install it on the transmission housing.

  1. Install the transmission hanger (A) and the 8 mm flange bolts finger-tight.

  1. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.

  1. Clean any dirt or oil from the change lever assembly sealing surface. Apply liquid gasket (P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S) to the sealing surface.
    NOTE: Do not install components if too much time has passed after applying the liquid gasket. Instead, remove the old residue and reapply the liquid gasket.

  1. Install the 8 x 10 mm dowel pins (A) and change lever assembly (B).

  1. Install the set screws (A), new 12 mm washers (B), springs (C), and steel balls (D).
  1. Install the new washer (E) and back-up light switch (F).

  1. Install the new washers (A), drain plug (B), filler plug (C), new O-ring (D), and vehicle speed sensor (VSS) (E).