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SECONDARY SHAFT (NO.1) COMPONENTS ASSEMBLY

D6E051517040107

1. Assemble in the order shown in the figure.

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

## 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} | -