2. Install the front oil seal of the drive shaft using the special tool (09431-21000).
Warning. Do not reuse oil seal.
3. Install the secondary shaft oil guide.
4. Using a special tool (09532-11500) install the outer ring of the secondary shaft bearing.
5. Install the control shaft assembly.
6. Install the differential gear assembly.
7. Install the drive shaft in the housing and the secondary shaft assembly.
8. Reinstall the shift rod assemblies.
1) Set the synchronizer sleeve of the first and second gears in neutral position.
2) Set the third and fourth gear synchronizer sleeve in neutral position.
3) Install the shift rod and fork assemblies.
9. Installing the spring pin.
1) Install the spring pins using a special tool (09414-11100) or a beard with a thin cylindrical end.
2) When installing, make sure that the slot. spring pin aligned with the center line of the rod.
Warning. Spring pins are not reusable.
10. Install the reverse gear.
11. Install the reverse lever.
12. Using a special tool (09461-21200) install the input shaft oil seal in the gearbox housing.
Warning. The oil seal is not reusable.
13. Install the secondary shaft bearing outer ring and spacer sleeve using special tools (09500-11000, 09432-22100A).
14. Installing the spacer sleeve.
1) Install two pieces of 3mm diameter solder onto the outer ring of the bearing as shown in the figure.
2) Temporarily install the gearbox housing and tighten the bolts to the specified torque, then remove the gearbox housing.
3) Remove the flattened solder.
4) Measure the thickness of the flattened solder. Select and install appropriate spacers.
| Axial play | Standard value, mm |
| Input shaft | 0.05-0.10 |
| Output shaft | 0.05-0.10 |
| Differential | 0.15-0.20 |
15. Install the oil guide into the gearbox housing.
16. Apply sealant to the mating surface of the gearbox housing.
Sealing agent: MS721-40.
17. Install the gearbox housing onto the clutch housing and tighten the bolts
Tightening torque
Gearbox housing failures - 35-42 Nm
18. Use a screwdriver to center the shaft.
19. Tighten the reverse gear shaft bolt to the specified torque.
Tightening torque
Reverse gear axle bolt - 43-55 Nm
20. Install the balls, springs and bolts with seals.
21. Using a special tool (09432-33300) install the secondary shaft gear.
22. Install the fifth gear pinion, needle roller bearing, synchronizer ring and synchronizer hub.
23. Install the fifth gear shift fork and synchronizer sleeve at the same time.
24. Installing the lock nut.
1) Using the control lever and selector lever, engage first gear.
2) Engage the fifth gear sleeve with the fifth gear pinion.
3) Tighten the lock nut to the specified torque.
25. Using a special tool (09414-11100) or a punch with a thin cylindrical end install the spring pin.
Warning. The spring pin is not reusable.
26. When installing, ensure that the slot in the spring pin is aligned with the center line of the gear shift rod.
27. Apply special sealant to the back cover and install the cover.
Sealing agent - MS 721-40
28. Install the speedometer driven gear assembly.
Tightening torque
Speedometer drive gear - 3-5 Nm
29. Install the reversing light switch.
30. Install the bracket.
31. Install the selector lever assembly.
Tightening torque
Shift lever assembly - 15-22 Nm