Secondary Shaft Reassembly

Secondary Shaft Reassembly

Special Tools Required

- Driver, 40 mm I.D. 07746-0030100
- Attachment, 30 mm I.D. 07746-0030300
- Wrench, 40 x 42 mm 07XAA-002010A
1. Install the thrust needle bearing (A), needle bearings (B), 2nd gear/park gear (C), thrust needle bearing (D), and splined washer (E) in the direction shown on the secondary shaft (F).

2. Wrap the shaft splines with tape, and install the new O-rings (G) in the 2nd clutch O-ring grooves, then remove the tape.
NOTE: To prevent damaging the O-rings, be sure to install the O-rings after installing the splined washer.

3. Install the 2nd clutch (H) on the secondary shaft, and secure the 2nd clutch with the snap ring (I).






4. Install the idler gear (A) in the direction shown, thrust needle bearing (B), 1st gear collar (C), needle bearing (D), 1st gear assembly (E), thrust needle bearing (F), and 52 mm washer (G) in the direction shown on the secondary shaft (H).
NOTE: The needle bearing contains the only two no-roller cavities (I); this is normal.

5. Wrap the shaft splines with tape, and install the new O-rings (J) in 1st/1st-hold clutch O-ring grooves, then remove the tape.
NOTE: To prevent damaging the O-rings, be sure to install the O-rings after installing the 1st gear collar and 52 mm washer.

6. Install the 1st/1st-hold clutch (K).






7. Install the ball bearing (A) over the 1st/1st-hold clutch guide (B) using the driver (40 mm I.D.), the attachment (30 mm I.D.), and the press.






8. Install the new splined washer (A) with the marked side (B) up over the ball bearing using the driver (40 mm I.D.), the attachment (30 mm I.D.), and the press.






9. Install the new locknut.






10. Place a V-block (A) on a vise (B), and put the secondary shaft (C) on the V-block and the vise.

11. Attach the wrench (40 x 42 mm) onto the top of the 1st clutch guide, and secure the wrench (40 x 42 mm) with the vise to hold the secondary shaft. Tighten the locknut to 178 N-m (18.2 kgf-m, 132 lbf-ft) with the torque wrench (D).
NOTE:

- Use a torque wrench to tighten the locknut. Do not use an impact wrench.

- The locknut has left-hand threads.





12. Stake the locknut to a depth (A) of 0.7-1.3 mm (0.03-0.05 in.) using a 3.5 mm punch (B).