Secondary Shaft

DISASSEMBLY / REASSEMBLY





NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

PRE-ASSEMBLY INSPECTION

2ND GEAR





1. Install the parts in the illustration above on the secondary shaft.

NOTE: Do not install the O-rings for this inspection.





2. Position the dial indicator against 2nd gear as shown.





3. Hold the thrust washer against the clutch assembly. Measure the 2nd gear axial clearance while moving 2nd gear.

Standard: 0.07 - 0.15 mm (0.003 - 0.006 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

4. If the clearance is out of tolerance, remove the splined washer and measure the thickness.





5. Select and install a new splined washer, then recheck.
6. After replacing the splined washer, make sure the clearance is within the tolerance.

1ST GEAR





1. Install the parts shown in the illustration above on the secondary shaft.

NOTE: Install the splined washer in the direction shown.








2. Measure the clearance between the splined washer and cotters with a feeler gauge.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

Standard: 0.07 - 0.15 mm (0.003 - 0.006 inch)

3. If the clearance is out of tolerance, remove the splined washer and measure the thickness.





4. Select and install the splined washer, then recheck.
5. After replacing the splined washer, make sure the clearance is within the tolerance.

ONE-WAY CLUTCH INSPECTION








1. Hold 1st gear, and make sure the secondary 1st clutch hub turns freely in the direction shown. Also make sure the secondary 1st clutch hub does not turn in the opposite direction.
2. If there is any problem, disassemble the 1st gear/ one-way clutch assembly, and inspect each part.

1ST GEAR / ONE-WAY CLUTCH OVERHAUL

Required Tools:
- 07749-0010000 Driver
- 07947-6340500 Driver Attachment
- 07746-0010600 Attachment, 72 x 75 mm
- 07HAD-SF10100 Driver Attachment
- 07746-0010500 Attachment, 62 x 68 mm


DISASSEMBLY





1. Remove the 1st-hold clutch hub using the special tools and a press as shown.





2. Separate the secondary 1st clutch hub from the 1st gear by turning the secondary 1st clutch hub in the direction shown.





3. Drive the ball bearing out from the secondary 1st clutch hub as shown, then remove the one-way clutch plate.
4. Remove the one-way clutch from the secondary 1st clutch hub.





5. Remove the ball bearing from the secondary 1st clutch hub using the special tools and a press.

ASSEMBLY

NOTE: Coat all parts with ATF during assembly.





1. Install the ball bearing in the gear-side of the secondary 1st clutch hub using the special tools and a press as shown.
2. Install the one-way clutch in the secondary 1st clutch hub.
3. Install the one-way clutch plate in the secondary 1st clutch hub.





4. Install the ball bearing in the secondary 1st clutch hub using the special tools and a press.





5. Assemble the secondary 1st clutch hub and 1st gear by turning the secondary 1st clutch hub.





6. Install the 1st-hold clutch hub in 1st gear using the special tools and a press as shown.
7. After the parts are assembled, inspect the one-way clutch operation.