Case And Extension

Dimension "L": 2 mm (0.08 in) or less 

Fig 1: Identifying Breather Tube Installation Dimension

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1. Install counter front bearing (1) to transmission case.
2. Apply recommended grease to roller of counter front bearing.
   Fig 2: Locating Counter Front Bearing

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3. Apply recommended sealant to mating surface of transmission case as shown in the figure below.
   Fig 3: Identifying Sealant Application Areas On Mating Surface Of Transmission Case

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   Dimension "B": 3 - 5 mm (0.12 - 0.20 in) 

   Sealant width "C": 1 - 2 mm (0.04 - 0.08 in) 

   Sealant height "C": 0.4 - 1 mm (0.016 - 0.04 in) 

   • Use Genuine Silicone RTV or an equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
   CAUTION:

   • Remove old sealant from the mounting surfaces. Also remove any moisture, oil, or foreign material from both mounting surfaces.
   • Apply sealant so as not to break the bead.
4. Install magnet to adapter plate.
5. Install transmission case to adapter plate.
   CAUTION:

   • Check for baffle plate weld bolt location while installing.
   • Check that magnet is within the specified area of adapter plate while installing.
   • Never drop counter front bearing.
   NOTE: Apply grease to magnet if it is difficult to keep magnet within the specified area of adapter plate.
   Fig 4: Identifying Transmission Case

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6. Install snap ring to main drive gear bearing using snap ring pliers.
   CAUTION: Never reuse snap ring.
   Fig 5: Removing/Installing Main Drive Gear Bearing Snap Ring Using Pliers

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1. Tighten baffle plate mounting nut (←) to the specified torque.
   Fig 6: Locating Baffle Plate Mounting Nut

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2. Install mounting bolt (←) to adapter plate and then tighten mounting bolt to the specified torque.
   Fig 7: Locating Adapter Plate Mounting Bolt

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1. Install front oil seal (1) to front cover using the drift (A) [SST: KV38102100 (J-25803-01)].

   Dimension "H": 8.55 - 9.55 mm (0.3366 - 0.3760 in) 

   Fig 8: Installing Front Oil Seal To Front Cover Using Drift

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   CAUTION: Never incline front oil seal.
2. Install front cover gasket and front cover to transmission case.
   CAUTION:

   • Never reuse front cover gasket.
   • Never damage front oil seal.
   • Remove any moisture, oil, or foreign material from both mating surfaces.
3. Temporarily tighten mounting bolt ←) and sealing bolt (1).
   Fig 9: Locating Front Oil Seal Mounting Bolt And Sealing Bolt

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4. Temporarily tighten mounting bolts (←) and sealing bolts (1).
   Fig 10: Locating Front Oil Seal Mounting Bolts And Sealing Bolts

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5. Tighten mounting bolts (←) and sealing bolts (1) to the specified torque in the numerical order as shown in the figure below.
   Fig 11: Locating Front Oil Seal Mounting Bolts And Sealing Bolts With Tightening Sequence

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1. Install oil gutter with the following procedure.
   1. Seat the prong of oil gutter in the groove on cap.
      Fig 12: Locating Reverse Idler Shaft Assembly

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   2. Install oil gutter (1) to rear extension and then tighten mounting bolt to the specified torque.
      Fig 13: Locating Oil Gutter

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2. Install striking rod oil seal to rear extension using the drift [SST: ST33061000 (J-8107-2)].
   CAUTION:

   • Never reuse striking rod oil seal.
   • Never incline striking rod oil seal.
3. Install dust cover to rear extension.
   Fig 14: Installing Striking Rod Oil Seal To Rear Extension Using Drift

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4. Install rear oil seal (1) to rear extension using the drift [SST: ST33400001 (J-26082)].

   Dimension "H": 1.2 - 2.2 mm (0.047 - 0.087 in) 

   Fig 15: Identifying Rear Oil Seal Installation Dimension

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   CAUTION: Never incline rear oil seal.
5. Apply recommended sealant to mating surface of rear extension as shown in the figure below.
   Fig 16: Identifying Sealant Application Areas On Mating Surface Of Rear Extension

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   Dimension "B": 3 - 5 mm (0.12 - 0.20 in) 

   Sealant width "C": 1 - 2 mm (0.04 - 0.08 in) 

   Sealant height "C": 0.4 - 1 mm (0.016 - 0.04 in) 

   • Use Genuine Silicone RTV or an equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
   CAUTION:

   • Remove old sealant from mounting surfaces. Also remove any moisture, oil, or foreign material from both mounting surfaces.
   • Apply sealant so as not to break the bead.
6. Install rear extension to adapter plate and then tighten mounting bolts (←) to the specified torque in the numerical order as shown in the figure below.
   CAUTION: Never damage rear oil seal and striking rod oil seal.

1. Apply gear oil to return spring plungers (1).
2. Install return spring plungers and return springs (2) to rear extension.

   Region	Return spring identification mark	Plunger groove
   RH	Brown	Without
   LH	Blue	With

   Fig 18: Locating Return Spring, Plungers And Plugs

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   CAUTION: The right and left return springs and return spring plungers are different, so make sure they are installed correctly.
3. Apply recommended sealant to threads of return spring plugs (3) and then tighten its to the specified torque.
   • Use Genuine Silicone RTV or an equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
   CAUTION: Remove old sealant and oil from threads.

1. Install plunger to rear extension.
   CAUTION: Be careful with orientation of plunger.
   Fig 20: Orientation Of Park/Neutral Position Switch Plunger

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2. Temporarily tighten park/neutral position (PNP) switch onto rear extension by rotating once or twice.
   CAUTION: Remove old sealant and oil from threads.
3. Apply recommended sealant to threads of park/neutral position (PNP) switch as shown in the figure below.
   • Use Genuine Silicone RTV or an equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
4. Tighten park/neutral position (PNP) switch to the specified torque.
   Fig 21: Identifying Sealant Application Areas On Park/Neutral Position Switch Threads

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1. Temporarily tighten back-up lamp switch onto rear extension by rotating once or twice.
   CAUTION: Remove old sealant and oil from threads.
2. Apply recommended sealant to threads of back-up lamp switch as shown in the figure below.
   • Use Genuine Silicone RTV or an equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
3. Tighten back-up lamp switch to the specified torque.
   Fig 22: Identifying Sealant Application Areas On Back-Up Lamp Switch Threads

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1. Install boot to striking rod oil seal and then install control rod to striking rod.
   CAUTION:

   • Be careful with the orientation of control rod.
     Fig 23: Orientation Of Control Rod

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   • Be careful with the orientation of boot (1).
   Fig 24: Orientation Of Boot

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2. Install retaining pin (←) to control rod using a pin punch [Commercial service tool].
   Fig 25: Locating Retaining Pin On Control Rod

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   CAUTION:

   • Never reuse retaining pin.
   • Assemble retaining pin from the direction shown by the arrow in the figure below, until it becomes flush with the end surface of control rod.
3. Install boot to control rod.
   CAUTION:

   • Be careful with the orientation of boot.
     Fig 26: Orientation Of Boot

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   • Fit control rod boot to the groove on control rod.
4. Install control rod boot to control rod.
   CAUTION: Fit control rod boot to the groove on control rod.

1. Install bracket (1) so that it contacts transmission case rib (A) and then tighten mounting bolt to the specified torque.
   CAUTION: Be careful with orientation of bracket.
2. Install bracket (2) so that it contacts rear extension side (B) and then tighten mounting bolt to the specified torque.
3. Install bracket (3) to rear extension and then tighten mounting bolts to the specified torque.
4. Install bracket (4) so that it contacts the projection (C) of rear extension and then tighten mounting bolt to the specified torque.
5. Install bracket (5) to rear extension and then tighten mounting bolt to the specified torque.
   Fig 27: Locating Transmission Assembly Brackets, Transmission Case Rib And Projection

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6. Install bracket (1) so that it contacts rear extension side (A) and then tighten mounting bolt to the specified torque.
7. Install bracket (2) to rear extension and then tighten mounting bolts to the specified torque.
   Fig 28: Locating Transmission Assembly Brackets And Transmission Case Rib

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1. Apply gear oil to check ball.
   CAUTION: Never drop check ball.
2. Install check ball and check select spring to rear extension.
   Fig 29: Locating Check Select Spring And Check Ball

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3. Install rear extension upper cover gasket and rear extension upper cover to rear extension.
   CAUTION:

   • Never reuse rear extension upper cover gasket.
   • Remove any moisture, oil, or foreign material from both mating surfaces.
4. Temporarily tighten rear extension upper cover mounting bolts while holding rear extension upper cover.
   CAUTION: Avoid tangling check select spring.
5. Tighten mounting bolts (←) to the specified torque in the numerical order as shown in the figure below.

Fig 30: Identifying Rear Extension Upper Cover Mounting Bolts Tightening Sequence

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1. Install gasket to drain plug and then install it to transmission case.
   CAUTION: Never reuse gasket.
2. Tighten drain plug to the specified torque.

1. Install gasket to filler plug and then install it to transmission case.
   CAUTION: Never reuse gasket.
2. Tighten filler plug to the specified torque.
   CAUTION: After gear oil is filled, tighten filler plug to the specified torque.