SECONDARY SHAFT COMPONENTS ASSEMBLY

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1.  Assemble in the order indicated in the table.

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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
Secondary shaft gear
6
Bearing (secondary shaft end)
(See Bearing (Secondary Shaft End) Assembly Note.)
7
Gear sleeve
(See Gear Sleeve Assembly Note.)
8
Friction damper
9
1st gear
(See 1st Gear, 1st Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note.)
10
Inner cone
11
Double cone
12
1st synchronizer ring
(See 1st Gear, 1st Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note.)
13
1st/2nd clutch hub component
(See 1st Gear, 1st Synchronizer Ring, and 1st/2nd Clutch Hub Component Assembly Note.)
14
Retaining ring
15
2nd synchronizer ring
(See 2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note.)
16
Double cone
17
Inner cone
18
2nd gear
(See 2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note.)
19
Friction damper
20
Secondary 3rd gear
(See 2nd Synchronizer Ring, 2nd Gear, and Secondary 3rd Gear Assembly Note.)
21
Retaining ring
22
Secondary 4th gear
(See Secondary 4th Gear and Bearing Assembly Note.)
23
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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1st/2nd synchronizer key size
A: 19.0 mm {0.748 in}
B: 4.25 mm {0.167 in}
C: 5.0 mm {0.20 in}


Bearing (Secondary Shaft End) Assembly Note

1.  Install the new bearing using the SST.

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Gear Sleeve Assembly Note

Note
•  If the secondary shaft gear replaced, install the gear sleeve the following procedures.

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

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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, double cone, inner cone, and 2nd gear.

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

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Secondary 4th Gear and Bearing Assembly Note

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

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2.  Measure the 1st gear thrust clearance using a dial indicator.

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•  If it exceeds the maximum specification, inspect the contact surfaces of the 1st gear, differential drive gear of the secondary shaft gear, and 1st/2nd clutch hub component. Replace worn and damaged parts.
1st gear thrust clearance
Standard: 0.05—0.28 mm {0.002—0.011 in}
Maximum: 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, inspect the contact surfaces of the 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub component. Replace worn and damaged parts.
2nd gear thrust clearance
Standard: 0.18—0.46 mm {0.007—0.018 in}
Maximum: 0.51 mm {0.020 in}