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SECONDARY SHAFT (NO.2) COMPONENTS ASSEMBLY

D6E051517040111

  Caution

  • Do not place the front bearing facing downward on a workbench after assembling the secondary shaft (NO.2) component. It may cause damage to the bearing roller guide.

1. Assemble in the order shown in the figure.

1 | Secondary shaft (No.2)
2 | Reverse needle bearing
3 | Reverse gear
4 | Reverse synchronizer ring
5 | Clutch hub
6 | Spring
7 | Synchronizer key
8 | Clutch hub sleeve
9 | Reverse clutch hub component (See Reverse Synchronizer Ring and Reverse Clutch Hub Component Assembly Note.)
10 | Snap ring (See Reverse Clutch Hub Snap Ring Assembly Note.)
11 | Spacer
12 | 5th needle bearing
13 | Spacer
14 | 5th gear
15 | 5th synchronizer ring
16 | Clutch hub
17 | Synchronizer key
18 | Spring
19 | Steel ball
20 | Clutch hub sleeve
21 | 5th/6th clutch hub component (See 5th Synchronizer Ring and 5th/6th Clutch Hub Component Assembly Note.)
22 | Snap ring (See 5th/6th Clutch Hub Snap Ring Assembly Note.)
23 | 6th synchronizer ring
24 | Spacer
25 | 6th needle bearing
26 | 6th gear
27 | Rear bearing (See Rear Bearing Assembly Note.)
28 | Snap ring (See Rear Bearing Snap ring Assembly Note.)
29 | Front bearing (See Front Bearing Assembly Note.)

## Reverse Synchronizer Ring and Reverse Clutch Hub Component Assembly Note

1. Assemble the reverse synchronizer ring, synchronizer key, key spring, and reverse clutch hub.

  Caution

  • Verify that the synchronizer ring, key, spring, and clutch hub are properly positioned.

2. Using the SST and a press, install the reverse clutch hub component.

## Reverse Clutch Hub Snap Ring Assembly Note

1. Install a new snap ring.

2. Measure the clearance between the reverse clutch hub and snap ring.

  • If not within the specification, select a suitable snap ring from the table below so that the clearance is within the specification.

  Clearance between reverse 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})
  --- | --- | --- | ---
  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}

## 5th Synchronizer Ring and 5th/6th Clutch Hub Component Assembly Note

1. Install the 5th synchronizer ring and 5th/6th clutch hub.

  Caution

  • Verify that the synchronizer ring and clutch hub are properly positioned.

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

3. Using the SST and a press, install the 5th/6th clutch hub component.

## 5th/6th Clutch Hub Snap Ring Assembly Note

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

2. Measure the clearance between the snap ring and the 5th/6th clutch hub.

  • If not within the specification, adjust it by selecting a proper snap ring from below.

  Clearance between 5th/6th 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}

## 6th Synchronizer Ring Assembly Note

1. Place the 6th synchronizer ring.

  Caution

  • Verify that the synchronizer ring and clutch hub are properly positioned.

## Rear Bearing Assembly Note

1. Install the SSTs and a press, and assemble the rear bearing.

## Rear Bearing Snap ring Assembly Note

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

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

  • 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} | -

## Front Bearing Assembly Note

1. Using the SST and a press, install the front bearing.