Secondary Shaft Reassembly

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. Wrap the shaft splines with electrical tape to prevent O-ring damage, install new O-rings (A) on the secondary shaft (B), then remove the tape.
   Fig 5: Locating O-Rings And Secondary Shaft

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7. Install the 2nd/5th clutch (C), the selected 2nd gear collar (D), the 39 x 57 x 2.5 mm thrust needle bearing (E), the 38 x 44 x 22.5 mm needle bearing (F), 2nd gear (G), and the 38 x 64 x 3.5 mm thrust needle bearing (H).
8. 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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9. Secure the idler gear (A) on the secondary shaft (B) in a bench vise with wood blocks, install a new 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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10. Install the 38 x 54 x 3.5 mm thrust needle bearing (A), the 37 x 52 x 2 mm thrust washer (B), the 32 x 38 x 34 mm needle bearing (C), 1st gear (D), the 37 x 50 x 2.5 mm thrust needle bearing (E), and the 37 x 49 x 3.4 mm thrust washer (F) on the secondary shaft (G).
    Fig 8: Locating 38 x 54 x 3.5 mm Thrust Needle Bearing, 37 x 52 x 2 mm Thrust Washer And 32 x 38 x 34 mm Needle Bearing

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11. Wrap the shaft splines with electrical tape, and install new O-rings (H) in the O-ring grooves, then remove the tape.
12. Install the 1st clutch (I) on the secondary shaft, and secure the 1st clutch with the 32 mm snap ring (J).
13. Install new sealing rings (K).