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: Identifying 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: Placing Idler Gear On Press Bases And Place Spacer Between 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: Identifying Thrust Needle Bearing, Needle Bearing, 5th Gear, Thrust Needle Bearing, 5th Gear Collar And Secondary Shaft

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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 Using 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: Identifying O-Rings, 2nd/5th Clutch, 2nd Gear Collar, Thrust Needle Bearing, Needle Bearing, 2nd Gear And Thrust Needle Bearing

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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 Using Driver Handle And Press

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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: Identifying Idler Gear, Secondary Shaft And Lock Bolt

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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: Identifying Needle Bearing, Thrust Washer, Needle Bearing, 1st Gear, Thrust Needle Bearing, Thrust Washer And Secondary Shaft

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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).