Secondary Shaft Reassembly

Secondary Shaft Reassembly

Special Tools Required

- Driver handle, 40 mm I.D. 07746-0030100
- Bearing driver attachment, 30 07746-0030300
- Wrench, 40 x 42 mm 07XAA-002010A
1. Install the thrust needle bearing (A), the needle bearings (B), the 2nd gear/park gear (C), the thrust needle bearing (D), and the splined washer (E) in the direction shown on the secondary shaft (F).

2. Wrap the shaft splines with tape, and install new O-rings (G) in the 2nd clutch O-ring grooves, then remove the tape.

NOTE: To prevent damage to the O-rings, be sure to install the O-rings after installing the splined washer.

3. Install the 2nd clutch (H) on the secondary shaft, and secure the 2nd clutch with the snap ring (I).






4. Install the idler gear (A) in the direction shown, the thrust needle bearing (B), the 1st gear collar (C), the needle bearing (D), the 1st gear assembly (E), the thrust needle bearing (F), and the 52 mm washer (G) in the direction shown on the secondary shaft (H).

NOTE: It is normal for the needle bearing (D) to have two cavities (I) without rollers.

5. Wrap the shaft splines with tape, and install new O-rings (J) in the 1st/1st-hold clutch O-ring grooves, then remove the tape.

NOTE: To prevent damage to the O-rings, be sure to install the O-rings after installing the 1st gear collar and the 52 mm washer.

6. Install the 1st/1st-hold clutch (K).






7. Install the ball bearing (A) over the 1st/1st-hold clutch guide (B) with the driver handle (40 mm I.D.), the bearing driver attachment (30), and a press.






8. Install a new splined washer (A) with the marked side (B) up over the ball bearing with the driver handle (40 mm I.D.), the bearing driver attachment (30), and the press.






9. Install a new locknut (A).






10. Place a V-block (A) on a vise (B), and put the secondary shaft (C) on the V-block and vise.

11. Attach the wrench (40 x 42 mm), onto the top of the 1st clutch guide, and secure the wrench (40 x 42 mm), with the vise to hold the secondary shaft. Tighten the locknut to 178 N-m (18.2 kgf-m, 132 lbf-ft) with the torque wrench (D).

NOTE:

- Use a torque wrench to tighten the locknut. Do not use an impact wrench.

- The locknut has left-hand threads.





12. Stake the locknut into the shaft to a depth (A) of 0.7-1.3 mm (0.03-0.05 in.) using a 3.5 mm punch (B).