SECONDARY SHAFT COMPONENTS ASSEMBLY

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1. Assemble in the order shown in the figure.

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1 | 1st/2nd clutch hub (See 1st/2nd Clutch Hub Assembly Note.)
2 | Synchronizer key
3 | Clutch hub sleeve (reverse gear)
4 | Synchronizer key spring
5 | Inner cone
6 | Double cone
7 | Synchronizer ring
8 | Secondary shaft gear
9 | Bearing (secondary shaft end) (See Bearing (Secondary Shaft End) Assembly Note.)
10 | 1st gear (See 1st Gear, 1st Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note.)
11 | Double cone component
12 | 1st/2nd clutch hub component (See 1st/2nd Clutch Hub Assembly Note.)
13 | Retaining ring
14 | Double cone component
15 | 2nd gear (See 2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note.)
16 | Friction damper
17 | Secondary 3rd gear (See 2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note.)
18 | Retaining ring
19 | Secondary 4th gear (See Secondary 4th Gear and Bearing Assembly Note.)
20 | Bearing (See Secondary 4th Gear and Bearing Assembly Note.)

1st/2nd Clutch Hub Assembly Note

1. Install the synchronizer key springs in the clutch hub with the hooks in the grooves to hold the three synchronizer keys in place.

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  Synchronizer key

  A: 19.00 mm {0.748 in}
  B: 4.25 mm {0.167 in}
  C: 5.00 mm {0.197 in}

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Bearing (Secondary Shaft End) Assembly Note

1. Install the new bearing using the SST.

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1st Gear, 1st Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note

1. Assemble the 1st gear, 1st synchronizer ring, inner cone, double cone and 1st/2nd clutch hub component, as shown in the figure.

2. Press the 1st/2nd clutch hub component on using the SST.

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2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note

1. Install the 2nd synchronizer ring and 2nd gear.

2. Install the secondary 3rd gear using the SSTs.

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Secondary 4th Gear and Bearing Assembly Note

1. Install the secondary 4th gear and the bearing using the SSTs.

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2. Measure the clearance between the 1st gear and the differential drive gear.

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  Standard clearance

  0.05—0.28 mm {0.002—0.011 in}

  Maximum clearance

  0.33 mm {0.013 in}

3. Measure the clearance between the 2nd gear and the secondary 3rd gear.

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  • If it exceeds the maximum specification, reassemble the secondary shaft component.

  Standard clearance

  0.18—0.51 mm {0.007—0.020 in}

  Maximum clearance

  0.56 mm {0.022 in}