Case And Extension

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

Fig 1: Identifying Breather Tube 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: Identifying Counter Front Bearing To Transmission Case

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3. Apply recommended sealant to mating surface of transmission case as shown in the figure below.
   Fig 3: Identifying Sealant Applying Area 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 on mounting surfaces. Also remove any moisture, oil, or foreign material on 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: Installing Snap Ring To Main Drive Gear Bearing Using Snap Ring 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) 

   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 on both mating surfaces.
   Fig 8: Installing Front Oil Seal To Front Cover Using Drift

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3. Temporarily tighten mounting bolt (<==) and sealing bolt (1).
   Fig 9: Locating Mounting Bolt

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4. Temporarily tighten mounting bolts (<==) and sealing bolts (1).
   Fig 10: Identifying 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: Mounting Bolts And Sealing Bolts 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

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

   CAUTION: Never incline rear oil seal.
   Fig 15: Installing Oil Seal To Rear Extension Using Drift

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5. Apply recommended sealant to mating surface of rear extension as shown in the figure below.
   Fig 16: Identifying Sealant Applying Area 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 on mounting surfaces. Also remove any moisture, oil, or foreign material on 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

   CAUTION: The right and left return springs and return spring plungers are different, so make sure they are installed correctly.
   Fig 18: Identifying Return Spring Plungers And Return Springs

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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 on threads.

1. Install plunger to rear extension.
   CAUTION: Be careful with orientation of plunger.
   Fig 20: Identifying Sealent Applying Area On Park/Neutral Position Switch

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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 on 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 Surface

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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 on 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 Surface

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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: Identifying Control Rod

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

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2. Install retaining pin (<==) to control rod using a pin punch [Commercial service tool].
   Fig 25: Identifying Boot Retaining Pin

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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: Locating Groove On Control Rod

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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: Identifying Brackets

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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.

1. Apply gear oil to check ball.
   CAUTION: Never drop check ball.
   Fig 28: Identifying Bracket Installing Position

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2. Install check ball and check select spring to rear extension.
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 on both mating surfaces.
4. Temporarily tighten rear extension upper cover mounting bolts while holding rear extension upper cover.
   CAUTION: Avoid tangling check select spring.
   Fig 29: Identifying Check Ball And Check Select Spring

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5. Tighten mounting bolts (<==) to the specified torque in the numerical order as shown in the figure below.

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.
   Fig 30: Tightening Sequence Of Rear Extension Upper Cover Mounting Bolts

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