SECONDARY SHAFT COMPONENTS ASSEMBLY

1. Assemble in the order indicated in the table.

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.

Synchronizer key

A: 19.0 mm {0.748 in}

B: 4.3 mm {0.17 in}

C: 5.0 mm {0.20 in}

Bearing (Secondary Shaft End) Assembly Note

1. Install the new bearing using the SST.

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

Note

• The size of the 1st, 2nd, 3rd, and 4th synchronizer rings are the same.

Be careful when installing them. The 2nd ring has the cut-out as shown in the figure.

• Align the synchronizer ring groove and clutch housing hub key when installing.

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

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

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 SST.

Secondary 4th Gear and Bearing Assembly Note

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

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

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.

• If not within the specification, reassemble the secondary shaft component.

Clearance

Standard: 0.18-0.46 mm {0.007-0.018 in}

Maximum: 0.51 mm {0.020 in}