Secondary Shaft Disassembly, Reassembly, and Inspection
Special Tools Required
Image Description/Tool Number
310166.png Driver Handle, 40 mm I.D. 07746-0030100
1. Secondary Shaft - Exploded View

Exploded View



NOTE: Refer to the Exploded View as needed during the following procedure.

1. Secondary Shaft - Disassemble
1.
Remove these parts in the following order:
-1.
Sealing rings (A)
-2.
32 mm snap ring (B)
-3.
1st clutch (C)
-4.
O-rings (D)
-5.
37 x 49 x 3.4 mm thrust washer (E)
-6.
37 x 50 x 2.5 mm thrust needle bearing (F)
-7.
1st gear (G)
-8.
32 x 38 x 34 mm needle bearing (H)
-9.
37 x 52 x 2 mm thrust washer (I)
-10.
38 x 54 x 3.5 mm thrust needle bearing (J)
2.
Secure the idler gear (A) in a bench vise with wood blocks.
3.
Remove the lock bolt (B).
NOTE: After this procedure, remove wood chips that may be stuck to the gear.
4.
Place the idler gear (A) on press bases (B).
5.
Place a spacer (C) between the secondary shaft and a press to prevent damaging the secondary shaft.
6.
Remove these parts in the following order using the press:
-1.
Ball bearing (A)
-2.
38 x 64 x 3.5 mm thrust needle bearing (B)
-3.
2nd gear (C)
-4.
38 x 44 x 22.5 mm needle bearing (D)
-5.
39 x 57 x 2.5 mm thrust needle bearing (E)
-6.
2nd gear collar (F)
-7.
2nd/5th clutch (G)
-8.
O-rings (H)
-9.
5th gear collar (I)
-10.
49 x 66 x 3 mm thrust needle bearing (J)
-11.
5th gear (K)
-12.
45 x 50 x 25 mm needle bearing (L)
-13.
49 x 66 x 3 mm thrust needle bearing (M)
-14.
Idler gear (N)

1. Secondary Shaft - Inspect
1.
Inspect the bearings for galling and rough movement.
2.
Inspect the shaft bearing surfaces for scoring and excessive wear.
3.
Inspect the shaft splines for excessive wear and damage.

2. Secondary Shaft 2nd Gear and 5th Gear Axial Clearance - Inspect

Inspect the secondary shaft 2nd gear and 5th gear axial clearance.

3. Secondary Shaft Installation Height - Inspect/Adjust

Inspect the secondary shaft installation height.


NOTE: Refer to the Exploded View as needed during the following procedure.

1. Secondary Shaft - Reassemble
1.
Place the idler gear (A) in the direction shown.
2.
Place the idler gear (A) on press bases (B).
3.
Place a spacer (C) between the secondary shaft (D) and a press to prevent damaging the secondary shaft.
4.
Install the idler gear using the press.
5.
Install these parts in the following order:
-1.
49 x 66 x 3 mm thrust needle bearing (A)
-2.
45 x 50 x 25 mm needle bearing (B)
-3.
5th gear (C)
-4.
49 x 66 x 3 mm thrust needle bearing (D)
-5.
5th gear collar (E)
6.
Press the 5th gear collar into place using the 40 mm I.D. driver handle and the press.
7.
Wrap the shaft splines with electrical tape to prevent O-ring damage.
8.
Install new O-rings (A).
NOTE: Lubricate the O-rings with ATF before installing them.
9.
Remove the electrical tape.
10.
Install these parts in the following order:
-1.
2nd/5th clutch (B)
-2.
Selected 2nd gear collar (C)
-3.
39 x 57 x 2.5 mm thrust needle bearing (D)
-4.
38 x 44 x 22.5 mm needle bearing (E)
-5.
2nd gear (F)
-6.
38 x 64 x 3.5 mm thrust needle bearing (G)
11.
Install the ball bearing (A).
12.
Press the ball bearing into place using the 40 mm I.D. driver handle and the press.
13.
Secure the idler gear (A) in a bench vise with wood blocks.
14.
Install a new lock bolt (B) to 78 N·m (8.0 kgf·m, 58 lbf·ft).
NOTE: After this procedure, remove wood chips that may be stuck to the gear.
15.
Install these parts in the following order:
-1.
38 x 54 x 3.5 mm thrust needle bearing (A)
-2.
37 x 52 x 2 mm thrust washer (B)
-3.
32 x 38 x 34 mm needle bearing (C)
-4.
1st gear (D)
-5.
37 x 50 x 2.5 mm thrust needle bearing (E)
-6.
37 x 49 x 3.4 mm thrust washer (F)
16.
Wrap the shaft splines with electrical tape to prevent O-ring damage.
17.
Install new O-rings (G).
NOTE: Lubricate the O-rings with ATF before installing them.
18.
Remove the electrical tape.
19.
Install these parts in the following order:
-1.
1st clutch (H)
-2.
32 mm snap ring (I)
-3.
New sealing rings (J)