SECONDARY SHAFT (NO.1) COMPONENTS ASSEMBLY

D6E051517040107

1. Assemble in the order shown in the figure.

1
Front bearing inner race
2
Snap ring
3
Secondary shaft (No.1)
4
1st gear
5
1st needle bearing
6
1st inner ring
7
1st middle ring
8
1st synchronizer ring
9
Clutch hub
10
Synchronizer key
11
Spring
12
Steel ball
13
Clutch hub sleeve
14
1st/2nd clutch hub component
15
2nd synchronizer ring
16
2nd middle ring
17
2nd inner ring
18
Steel ball
19
2nd gear
20
2nd needle bearing
21
2nd bearing inner race
22
Snap ring
23
Spacer
24
4th needle bearing
25
4th gear
26
4th inner ring
27
4th middle ring
28
4th synchronizer ring
29
Clutch hub
30
Synchronizer key
31
Spring
32
Steel ball
33
Clutch hub sleeve
34
3rd/4th clutch hub component
35
Snap ring
36
3rd synchronizer ring
37
3rd middle ring
38
3rd inner ring
39
3rd needle bearing
40
Spacer
41
3rd gear
42
Rear bearing
43
Snap ring

Front Bearing Inner Race Assembly Note

1. Install the front bearing inner race using the SSTs and a press.

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

1. Place the 1st gear, 1st inner ring, 1st middle ring, 1st synchronizer ring, 1st/2nd clutch hub.

Caution
• Align each clutch ring with the gear and clutch hub correctly.

2. Assemble the synchronizer key, spring, steel ball, and clutch hub sleeve as shown in the figure.

3. Press fit the 1st/2nd clutch hub component using the SST and a press.

2nd Synchronizer Ring and 2nd Gear Assembly Note

1. Place the 2nd synchronizer ring, 2nd middle ring, 2nd inner ring and 2nd gear.

Caution
• Align each clutch ring with the gear and clutch hub correctly.

2nd Bearing Inner Race Snap Ring Assembly Note

1. Install a new snap ring to the secondary shaft.

2. Measure the clearance between the 2nd inner race and the snap ring.

• If not within the specification, adjust it by selecting a proper snap ring from below.
Clearance between 2nd bearing inner race and snap ring
0.0-0.1 mm {0.0000-0.0039 in}
Snap ring size

Identification mark

Thickness (mm {in})

Identification mark

Thickness (mm {in})

A
2.25 {0.089}
E
2.45 {0.096}
B
2.30 {0.091}
F
2.50 {0.098}
C
2.35 {0.093}
G
2.55 {0.100}
D
2.40 {0.094}
H
2.60 {0.102}

4th Gear, 4th Synchronizer Ring and 3rd/4th Clutch Hub Component Assembly Note

1. Place the 4th gear, 4th inner ring, 4th middle ring, 4th synchronizer ring and 3rd/4th clutch hub.

Caution
• Align each clutch ring with the gear and clutch hub correctly.

2. Assemble the synchronizer key, spring, steel ball, and clutch hub sleeve as shown in the figure.

3. Install the 3rd/4th clutch hub component using the SST and a press.

3rd/4th Clutch Hub Snap Ring Assembly Note

1. Install a new snap ring to the secondary shaft.

2. Measure the clearance between the 3rd/4th clutch hub and the snap ring.

• If not within the specification, adjust it by selecting a proper snap ring from below.
Clearance between 3rd/4th clutch hub and snap ring
0.0-0.1 mm {0.0000-0.0039 in}
Snap ring size

Identification mark

Thickness (mm {in})

Identification mark

Thickness (mm {in})

1
2.25 {0.089}
4
2.40 {0.094}
2
2.30 {0.091}
5
2.45 {0.096}
3
2.35 {0.093}
6
2.50 {0.098}

3rd Gear and 3rd Synchronizer Ring Assembly Note

1. Place the 3rd synchronizer ring, 3rd middle ring, 3rd inner ring and 3rd gear.

Caution
• Align each clutch ring with the gear and clutch hub correctly.

Rear bearing Assembly Note

1. Install the rear bearing using the SSTs and a press.

Rear Bearing Snap Ring Assembly Note

1. Install a new snap ring to the secondary shaft.

2. Measure the clearance between the rear bearing inner race and the snap ring.

• If not within the specification, adjust it by selecting a proper snap ring from below.
Clearance between rear bearing inner race and snap ring
0.0-0.1 mm {0.0000-0.0039 in}
Snap ring size

Identification mark

Thickness (mm {in})

Identification mark

Thickness (mm {in})

B
1.85 {0.073}
0
2.05 {0.081}
C
1.90 {0.075}
1
2.10 {0.083}
D
1.95 {0.077}
2
2.15 {0.085}
E
2.00 {0.079}
-