Page 2617 of 2898
SMT839
ASSEMBLYNJMT00501. Attach side gear thrust washers to side gears and install in
differential case.
2. Install pinion mate thrust washers and pinion mate gears.
SMT087A
3. Insert pinion mate shaft.
+When inserting, be careful not to damage pinion mate
thrust washers.
SMT610AB
4. Measure clearance between side gear and differential case
with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
SMT611A
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.
Differential side gear thrust washer:
Refer to SDS, MT-121.
SMT147AA
5. Install retaining pin.
+Make sure that retaining pin is flush with case.
REPAIR FOR COMPONENT PARTSRS5F30A
Final Drive (Cont'd)
MT-45
Page 2618 of 2898
SMT609A
6. Install final gear.
+Apply locking sealant to final gear fixing bolts before
installing them.
7. Install speedometer drive gear and stopper.
SMT648
8. Press on differential side bearings.
SMT086C
Shift Control Components
INSPECTIONNJMT0051+Check contact surface and sliding surface for wear, scratches,
projections or other damage.
SMT660A
Case Components
DISASSEMBLY AND ASSEMBLYNJMT0052Input Shaft Oil SealNJMT0052S011. Drive out input shaft oil seal.
SMT751BA
2. Install input shaft oil seal.
+Apply multi-purpose grease to seal lip of oil seal before
installing.
REPAIR FOR COMPONENT PARTSRS5F30A
Final Drive (Cont'd)
MT-46
Page 2619 of 2898
SMT688C
Input Shaft Rear BearingNJMT0052S021. Remove welch plug from transmission case.
SMT633
2. Remove input shaft rear bearing by tapping it from welch plug
hole.
SMT634
3. Install welch plug.
+Apply recommended sealant to mating surface of trans-
mission case.
SMT635-A
4. Install input shaft rear bearing.
SMT636-A
Mainshaft Front Bearing Outer Race and Oil ChannelNJMT0052S031. Remove mainshaft front bearing outer race.
2. Remove oil channel.
REPAIR FOR COMPONENT PARTSRS5F30A
Case Components (Cont'd)
MT-47
Page 2620 of 2898
SMT595
3. Install oil channel.
+Ensure the oil groove faces the oil pocket.
SMT752BA
4. Install mainshaft front bearing outer race.
Mainshaft Rear Bearing Outer RaceNJMT0052S04+Refer to ªMainshaft Bearing Preloadº, MT-121.
Differential Side Bearing Outer RaceNJMT0052S06+Refer to ªDifferential Side Bearing Preloadº, MT-121.
REPAIR FOR COMPONENT PARTSRS5F30A
Case Components (Cont'd)
MT-48
Page 2621 of 2898

NJMT0091
Differential Side Bearing PreloadNJMT0091S01If any of the following parts are replaced, adjust differential side
bearing preload.
+Differential case
+Differential side bearing
+Clutch housing
+Transmission case
SMT645-A
1. Remove differential side bearing outer race (transmission case
side) and shim(s).
SMT646-A
2. Reinstall differential side bearing outer race without shim(s).
3. Install final drive assembly on clutch housing.
4. Install transmission case on clutch housing.
+Tighten transmission case fixing bolts to the specified
torque. Refer to MT-30.
SMT454-A
5. Set dial indicator on front end of differential case.
6. Insert Tool all the way into differential side gear.
7. Move Tool up and down and measure dial indicator deflection.
8. Select shim considering bearing preload.
Suitable shim thickness =
Dial indicator deflection + specified bearing preload
Differential side bearing preload and adjusting shims:
Refer to SDS, MT-121, MT-122.
9. Install selected shim(s) and differential side bearing outer race.
10. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
+Tighten transmission case fixing bolts to the specified
torque. Refer to MT-30.
ADJUSTMENTRS5F30A
Differential Side Bearing Preload
MT-49
Page 2622 of 2898

SMT600-A
c. Measure turning torque of final drive assembly.
Turning torque of final drive assembly (New bearing):
Refer to SDS, MT-121.
+When old bearing is used again, turning torque will be
slightly less than the above.
+Make sure torque is close to the specified range.
+Changes in turning torque of final drive assembly per
revolution should be within 1.0 N´m (10 kg-cm, 8.7 in-lb)
without binding.
Mainshaft Bearing PreloadNJMT0091S02If any of the following parts are replaced, adjust mainshaft bearing
preload.
+Mainshaft
+Mainshaft bearings
+Clutch housing
+Transmission case
SMT613AB
1. Remove case cover, O-ring, spacer, mainshaft rear bearing
adjusting shim and mainshaft rear bearing outer race from
transmission case.
2. Install mainshaft assembly on clutch housing.
3. Install transmission case on clutch housing.
+Tighten transmission case fixing bolts to the specified
torque. Refer to MT-30.
SMT650A
4. Install mainshaft rear bearing outer race on inner race.
SMT599
5. Measure distance (ª!º) from transmission case to bearing outer
race.
+Make sure that bearing is properly seated.
6. Select shim considering bearing preload.
Suitable shim thickness = measure distance (ª!º) þ 12.5 mm
(0.492 in) + (specified bearing preload)
Mainshaft rear bearing preload and adjusting shims:
Refer to SDS, MT-121, MT-121.
7. Check total turning torque after assembling. Refer to
ªASSEMBLYº, MT-51.
ADJUSTMENTRS5F30A
Differential Side Bearing Preload (Cont'd)
MT-50
Page 2623 of 2898
NJMT0092
SMT586
1. Install striking rod, lever and interlock.
+Tape edges of striking rod to avoid damaging oil seal lip
during installation.
+When taped edges of striking rod are past the oil seal,
remove tape.
SMT584
2. Install reverse check sleeve assembly.
3. Install check balls, reverse check spring and check plug.
SMT688
4. Check reverse check turning torque (At striking rod).
Reverse check turning torque (At striking rod):
Refer to SDS, MT-119.
+If not within specification, select another check plug having a
different length and reinstall it.
Reverse check plug:
Refer to SDS, MT-119.
5. Install selected reverse check plug.
+Apply locking sealant to thread of plug before installing it.
SMT648AA
6. Install check ball plug, shift check ball and shift check spring.
7. Install oil pocket.
SMT580
8. Install gear components onto clutch housing.
a. Install final drive assembly and reverse idler gear.
ASSEMBLYRS5F30A
MT-51
Page 2624 of 2898
SMT737A
b. Install mainshaft and input gear as a set.
+Take care not to damage oil seal lip with splines of input
shaft while shaft is being inserted into clutch housing.
+Take care not to damage oil channel when inserting main-
shaft into clutch housing.
SMT577
c. Install bearing retainer.
+One of these three screws is torx type and should be
installed with suitable tool, as shown.
SMT664
d. After installing torx screw, stake it at two points.
SMT666
9. Apply grease to shifter caps, then install it to control bracket.
Install control bracket with 1st & 2nd shift fork.
10. Install 3rd & 4th and 5th shift forks.
SMT596
11. Insert fork shaft.
+Apply multi-purpose grease to support spring before
installing.
12. Install reverse idler spacer.
ASSEMBLYRS5F30A
MT-52