Secondary Shaft Assembly

Disassembly & Inspection





1. Measure thrust clearance of 1st gear and 2nd gear before disassembly.
2. Disassemble in order shown in figure.
3. Assembly will be in reverse order of disassembly.

Preinspection
Secondary 1st gear thrust clearance





1. Measure clearance between secondary 1st gear and differential drive gear.
Clearance: 0.002 - 0.011 inch (0.05 - 0.28 mm)
Maximum: 0.011 inch (0.29 mm)
2. If clearance exceeds maximum, check contact surfaces of secondary 1st gear, differential drive gear of secondary shaft, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.

Secondary 2nd gear thrust clearance





1. Measure clearance between secondary 2nd gear and secondary 3rd gear.
Clearance: 0.002 - 0.0067 inch (0.05 - 0.17 mm)
Maximum: 0.010 inch (0.27 mm)
2. If clearance exceeds maximum, check contact surfaces secondary of 2nd gear, secondary 3rd gear, and 1st/2nd clutch hub assembly. Replace worn and damaged parts.

Disassembly note
Bearing and secondary 4th gear





Remove bearing and secondary 4th gear by using SST(OK 201 172 008).

Secondary 3rd gear and secondary 2nd gear
1. Shift gears to 1st gear.





2. Remove secondary 3rd gear and secondary 2nd gear by using SST (OK 201 172 008).

Inspection

Notice: Inspect all parts and repair or replace as necessary.

Gears
1. Inspect synchronizer cones for wear.
2. Inspect gear teeth for damage, wear, and cracks.





3. Inspect synchronizer ring matching teeth for damage and wear.

Synchronizer ring
1. Inspect synchronizer ring teeth for damage, wear, and cracks.





2. Inspect tapered surface for wear and cracks.
3. Set synchronizer ring squarely in gear.





4. Measure clearance between synchronizer ring and flank surface of gear.
Standard clearance: 0.055 - 0.067 inch (1.4 - 1.7 mm)
Minimum: 0.031 inch (0.8 mm)

Clutch hub assembly
1. Inspect clutch hub sleeve and hub operation.
2. Inspect gear teeth for damage, wear, and cracks.





3. Inspect synchronizer keys for damage, wear, and cracks.





4. Measure clearance between clutch hub sleeves and shift forks.





Clearance chart
in. (mm)

Reverse idle gear and reverse lever
1. Inspect gear teeth for damage, wear, and cracks.





2. Measure clearance between reverse idle gear bushing and reverse lever.
Standard clearance: 0.0037 - 0.013 inch (0.095 - 0.33 mm)
Maximum: 0.012 inch (0.31 mm)

Bearing





1. Inspect for damage and rough rotation.

Primary shaft and secondary shaft
1. Inspect gear contact surface for damage and wear.
2. Inspect splines for damage and wear.
3. Inspect gear teeth for damage, wear, and cracks.
4. Inspect oil passage for clogging.





5. Measure primary and secondary shaft runout.
Secondary shaft runout: 0.0006 inch (0.015 mm) max.




Oil clearance chart
in. (mm)

Notice: If shaft is replaced, adjust bearing preload.

Assembly note
Clutch hub









Synchronizer key dimensions chart
in. (mm)





1. Install synchronizer keys and springs in clutch hub.

Bearing (differential drive gear end)





1. Install new bearing by using SST(OK900 175 AA1).

Secondary 1st gear, 1st synchronizer ring and 1st/2nd clutch hub assembly
1. Assemble secondary 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly, as shown in figure.





2. Align synchronizer ring grooves and synchronizer keys.





3. Press on 1 strand clutch hub assembly by using SST (OK 900 175 AA1).

2nd synchronizer ring, 2nd gear and secondary 3rd gear
1. Install 2nd synchronizer ring and secondary 2nd gear.





2. Install secondary 3rd gear by using SST (OK 900 175 AA1).

Secondary 4th gear and bearing inner race





1. Install secondary 4th gear and bearing inner race by using SST (OK 900 175 AA1).





2. Measure clearance between 1st gear and differential drive gear.
Clearance: 0.002 - 0.011 inch (0.05 - 0.28 mm)
Maximum: 0.011 inch (0.29 mm)





3. Measure clearance between secondary 2nd gear and secondary 3rd gear.
Clearance: 0.004 - 0.008 inch (0.10 - 0.22 mm)
Maximum: 0.010 inch (0.27 mm)
4. If not as specified, disassemble and reassemble secondary shaft assembly.