2. Install the spring washer and washer at an angle to the clutch housing as shown in the figure.
3. Insert the secondary and intermediate shafts into the shift forks and install them as an assembly.
Note: Before installing the secondary and intermediate shaft assemblies, wrap the splined portion of the secondary shaft with electrical tape to protect it.
6. Wrap the splined portion of the secondary shaft with electrical tape.
4. Install the reverse idler gear and reverse idler gear shaft into the clutch housing.
5. Install the reverse shift fork holder into the clutch housing by inserting the 5th/Reverse shift pin into the reverse shift fork groove.
6. Install the reverse gear lock cam onto the clutch housing.
7. Install the oil seal.
8. Install the gear selector lever, spring washer and springs onto the clutch.
9. Install the gear selector lever and spring pin.
10. Tighten the gear selector spring bolt.
11. Install the M oil transfer plate, 78mm washer and oil groove into the gearbox housing.
Note: Please select 78mm washer according to the measurements above.
12. Apply sealant to the mating surface of the gearbox housing as shown in the figure.
Note:
- Use sealant (P/N 08С70 - К0234М).
- Remove any dirty liquid from the contact surfaces.
- To prevent fluid leakage, seal the bolt holes around their entire circumference.
- If 20 minutes have passed since applying the sealant, apply it again and reassemble the crankcases.
- Allow the sealant to cure for at least 20 minutes after assembly before refilling the transmission with oil.
13. Install 14x20 reference pins.
14. Install the limiter ring as shown in the figure. Place the gearbox housing on the clutch housing, carefully aligning the shafts.
Note: Align the limiter ring with the 5th gear shift fork.
15. Lower the gearbox housing and use pliers to install the retaining ring into the intermediate shaft bearing groove.
16. Make sure the snap ring is securely seated in the intermediate shaft bearing groove.
- Size A after installation: 3.6-6.3 mm
17. Screw in the 32mm plug.
Note: Apply thread sealant (P/N 0Y740-99986 or 08C70-X0134S).
18. Install the transmission hanger bracket, then tighten the bolts in a cross pattern in several passes as shown in the figure.
19. Install the flange bolt, washers, drain plugs and filler plugs.
20. Install the steel balls, springs, washers, ball lock screws and reverse light switch.
21. Install the vehicle speed sensor (VSS).
22. Turn the gear selector lever and shift rod shaft counterclockwise, then insert the shift rod shaft.
23. Align the groove of the shift rod A and the gear selector rod finger by turning the shift rod shaft and the gear selector lever counterclockwise, then install the shift rod shaft assembly.
24. Apply sealant (P/N 08С70 - К0234М) to the threads, screw in the retainer bolt.
25. Apply sealant to the surface of the shift lever cover as shown in the figure.
Note:
- Use sealant P/N 08С70-К0234М.
- Remove any dirty liquid from the contact surfaces.
- To prevent fluid leakage, seal the bolt holes around their entire circumference.
- If 20 minutes have passed since applying the sealant, apply it again and reassemble the crankcases.
- Allow the sealant to cure for at least 20 minutes after assembly before refilling the transmission with oil.
26. Install the shift linkage cover assembly.
27. Install the transfer case assembly or left cover.
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