Secondary Shaft 2nd Gear and 5th Gear Axial Clearance Inspection

Special Tools Required 

Driver Handle, 40 mm I.D. 07746-0030100

1. Slide the idler gear (A) over the secondary shaft (B) in the direction shown.
   Fig 1: Locating Idler Gear And Secondary Shaft

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2. Place the idler gear (A) on press bases (B), and place a spacer (C) between the secondary shaft (D) and the press to prevent damaging the secondary shaft.
   Fig 2: Locating Idler Gear, Press Bases, Spacer And Secondary Shaft

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3. Install the idler gear using a press.
4. Install the 49 x 66 x 3 mm thrust needle bearing (A), the 45 x 50 x 25 mm needle bearing (B), 5th gear (C), the 49 x 66 x 3 mm thrust needle bearing (D), and the 5th gear collar (E) on the secondary shaft (F).
   Fig 3: Locating 49 x 66 x 3 mm Thrust Needle Bearing, 45 x 50 x 25 mm Needle Bearing And 5th Gear

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5. Press the 5th gear collar into place using the 40 mm I.D. driver handle and the press.
   Fig 4: Pressing 5th Gear Collar Into Place Using 40 mm I.D. Driver Handle And Press

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6. Install the 2nd/5th clutch (A) and the 2nd gear collar (B) on the secondary shaft (C).
   Fig 5: Locating 2nd/5th Clutch, 2nd Gear Collar And Secondary Shaft

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7. Install the ball bearing (A) over the secondary shaft (B), then press it into place using the 40 mm I.D. driver handle and the press.
   Fig 6: Installing Ball Bearing Over Secondary Shaft

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8. Secure the idler gear (A) on the secondary shaft (B) in a bench vise with wood blocks, install the old lock bolt (C), and tighten it 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.
   Fig 7: Securing Idler Gear On Secondary Shaft In Bench Vise With Wood Blocks

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9. Measure the clearance between the 2nd gear collar (A) and the ball bearing (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.

   Standard: 0.05-0.12 mm (0.002-0.004 in) 

   Fig 8: Measuring Clearance Between 2nd Gear Collar And Ball Bearing With Feeler Gauge

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10. If the clearance is out of the standard, remove the 2nd gear collar and measure its height.
    Fig 9: Checking 2nd Gear Collar Height

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11. Select and install a new 2nd gear collar, then recheck the clearance.

    2ND GEAR COLLAR 

    2ND GEAR COLLAR HEIGHT REFERENCE CHART
    
    

    No.	Height
    A	32.89 mm (1.2949 in)
    B	32.94 mm (1.2968 in)
    C	32.99 mm (1.2988 in)
    D	33.04 mm (1.3008 in)
    E	33.09 mm (1.3028 in)
    F	33.14 mm (1.3047 in)
    G	33.19 mm (1.3067 in)
    H	33.24 mm (1.3087 in)