Secondary Shaft Reassembly

Secondary Shaft Reassembly

Special Tools Required

- Driver handle, 40 mm I.D. 07746-0030100
- Attachment, 30 mm I.D. 07746-0030300
- Wrench, 40 x 42 mm 07XAA-002010A
1. Install the 44 x 66 x 3.5 mm thrust needle bearing (A), the needle bearings (B), the 2nd gear/park gear (C), the 44 x 66 x 3.5 mm thrust needle bearing (D), and the splined washer (E) in the direction shown on the secondary shaft (F).

2. Wrap the shaft splines with tape, and install new O-rings (G) in the 2nd clutch O-ring grooves, then remove the tape.
NOTE: To prevent damage to 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, the 43.5 x 59 x 2.5 mm thrust needle bearing (B), the 1st gear collar (C), the needle bearing (D), the 1st gear assembly (E), the 40 x 57 x 2.5 mm thrust needle bearing (F), and the 52 mm washer (G) in the direction shown on the secondary shaft (H).
NOTE: The needle bearing contains two no-roller cavities (I); this is normal.

5. Wrap the shaft splines with tape, and install new O-rings (J) in the 1st/1st-hold clutch O-ring grooves, then remove the tape.
NOTE: To prevent damage to the O-rings, be sure to install the O-rings after installing the 1st gear collar and the 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 40 mm driver handle, the 30 mm attachment, and a press.






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






9. Install a 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 40 x 42 mm wrench onto the top of the 1st clutch guide, and secure the 40 x 42 mm wrench with the vise to hold the secondary shaft. Tighten the locknut to 178 N-m (18.2 kgf-m, 132 lbf-ft) using a torque wrench (D).
NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.






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).