2. Install the spring washer and washer at an angle to the clutch housing as shown.
3. Insert the secondary and intermediate shafts into the shift forks and install them as an assembly.
Note: Before installing the output shaft and countershaft assembly, wrap the output shaft spline with electrical tape to protect it.
6. Wrap the spline of the secondary shaft with electrical tape.
4. Install the reverse idle gear and reverse idle 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 groove of the reverse shift fork.
6. Install the reverse lock cam to the clutch housing.
7. Install the gland.
8. Install the gear selector, spring washer and springs on the leash.
9. Install gear selector and spring pin.
10. Tighten the gear selection spring bolt.
11. Install oil distributor plate M, 78mm washer and oil chute into the gearbox housing.
Note: Select a 78mm washer according to the measurements above.
12. Apply sealant to the contact surface of the gearbox housing as shown in the illustration.
Note:
- Use sealant (P/N 08C70 - K0234M).
- Remove dirty liquid from contact surfaces.
- Seal the bolt holes around their entire circumference to prevent fluid leakage.
- If 20 minutes have passed since the sealant was applied, apply it again and reassemble the crankcases.
- Before filling the gearbox with oil, allow the sealant to cure for at least 20 minutes after assembly.
13. Install the 14x20 reference pins.
14. Install the restrictor ring as shown. Place the gearbox housing on the clutch housing, carefully aligning the shafts.
Note: Align the limiter ring with the 5th shift fork.
15. Lower the gearbox housing and use pliers to install the circlip into the countershaft bearing groove.
16. Make sure the retaining ring is securely seated in the countershaft bearing groove.
- Dimension A after installation: 3.6-6.3mm
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 crosswise in several passes as shown.
19.Install the shoulder bolt, washers, drain and filler plugs.
20. Install the steel balls, springs, washers, ball retaining screws and reversing light switch.
21. Install the vehicle speed sensor (VSS).
22. Turn the gear selector lever and shifter shaft counterclockwise, then insert the shifter shaft.
23. Align the groove of shifter A and the shifter pin by turning the shifter axle and selector lever counterclockwise, then install the shifter axle assembly.
24. Apply sealant (P/N 08C70 - K0234M) onto the thread, screw in the retainer bolt.
25. Apply sealant to the surface of the shifter cover as shown in the illustration.
Note:
- Use sealant P/N 08C70-K0234M.
- Remove dirty liquid from contact surfaces.
- Seal the bolt holes around their entire circumference to prevent fluid leakage.
- If 20 minutes have passed since the sealant was applied, apply it again and reassemble the crankcases.
- Before filling the gearbox with oil, allow the sealant to cure for at least 20 minutes after assembly.
26. Install shifter cover assembly.
27. Install the transfer case assembly or left cover.