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SECONDARY SHAFT COMPONENTS ASSEMBLY

BME051517301M04

1. Assemble in the order indicated in the table.

1 | Secondary shaft
2 | Reverse main gear (See Reverse Main Gear Assembly Note.)
3 | 1st bushing (See 1st Bushing Assembly Note.)
4 | 1st needle bearing
5 | 1st gear
6 | 1st inner synchronizer component
7 | Synchronizer key spring (See Synchronizer Key Spring, 1st/2nd Synchronizer Key and 1st/2nd Clutch Hub and Sleeve Assembly Note.)
8 | 1st/2nd synchronizer key
9 | 1st/2nd clutch hub and sleeve
10 | 1st/2nd clutch hub set (See 1st/2nd Clutch Hub Set Assembly Note.)
11 | 2nd inner synchronizer component
12 | 2nd bushing (See 2nd Bushing Assembly Note.)
13 | 2nd needle bearing
14 | 2nd gear
15 | 3rd gear (See 3rd Gear Assembly Note.)
16 | 3rd/4th secondary shaft spacer
17 | 4th gear adjustment shim (See 4th Gear Adjustment Shim Assembly Note.)
18 | 4th gear (See 4th Gear Assembly Note.)
19 | 5th gear (See 5th Gear Assembly Note.)
20 | 5th gear Snap ring (See 5th Gear Snap Ring Assembly Note.)
21 | Secondary shaft rear bearing (See Secondary Shaft Rear Bearing Assembly Note.)
22 | Secondary shaft C ring (See Secondary Shaft C Ring Assembly Note.)
23 | C ring holder
24 | Snap ring
25 | Snap ring
26 | Secondary shaft rear bearing adjust shim

## Reverse Main Gear Assembly Note

1. Place a new reverse main gear with the bevel edge facing toward the engine.

2. Install the reverse main gear using the SST.

## 1st Bushing Assembly Note

  Caution

  • The shaft can be damaged when installing the 1st bushing if the SST touchedes the secondary shaft. Install the SST to the shaft without touching the shaft.

1. Place the 1st bushing, and assemble the SST as shown in the figure.

2. Install the 1st bushing using the SSTs.

## Synchronizer Key Spring, 1st/2nd Synchronizer Key and 1st/2nd Clutch Hub and Sleeve Assembly Note

1. Install the synchronizer key spring, 1st/2nd synchronizer key and 1st/2nd clutch hub to the 1st/2nd clutch sleeve.

  (1) Install a new 1st/2nd clutch hub in the direction as shown in the figure.
  (2) Install the 1st/2nd clutch sleeve in the direction as shown in the figure.
  (3) Install center projection parts of synchronizer key springs to different synchronizer keys at each side.

## 1st/2nd Clutch Hub Set Assembly Note

  Note

  • Align the synchronizer ring grooves with the synchronizer key during assembly.

1. Install the 1st/2nd clutch hub set using the SSTs.

## 2nd Bushing Assembly Note

1. Install the 2nd bushing using the SSTs.

## 3rd Gear Assembly Note

1. Place a new 3rd gear in the direction as shown in the figure.

2. Install the 3rd gear using the SST.

## 4th Gear Adjustment Shim Assembly Note

1. Install the 4th gear adjustment shim washer.

2. Measure length C2 as shown in the figure.

  • If not within the specification, adjust it by selecting a proper 4th gear adjustment shim from below.
  • Select only one 4th gear adjustment shim.

Specification C2

  173.85-173.95 mm {6.844-6.848 in}

4th gear adjustment shim size

Thickness (mm {in})
0.52 {0.021} | 0.84 {0.033}
0.60 {0.024} | 0.92 {0.036}
0.68 {0.027} | 1.00 {0.039}
0.76 {0.030} | 1.08 {0.043}

## 4th Gear Assembly Note

1. Place a new 4th gear in the direction as shown in the figure.

2. Install the 4th gear using the SST.

## 5th Gear Assembly Note

1. Place a new 5th gear in the direction as shown in the figure.

2. Install the 5th gear using the SSTs.

## 5th Gear Snap Ring Assembly Note

1. Install a new 5th gear snap ring to the secondary shaft.

2. Measure the clearance between the 5th gear snap ring and the 5th gear.

  • If not within the specification, adjust it by selecting a proper snap ring from below.

Clearance

  0.0-0.1 mm {0.0000-0.0039 in}

5th gear snap ring size

Thickness (mm {in})
1.85 {0.073} | 2.05 {0.081}
1.90 {0.075} | 2.10 {0.083}
1.95 {0.077} | 2.15 {0.085}
2.00 {0.079} | 2.20 {0.087}

## Secondary Shaft Rear Bearing Assembly Note

1. Install the secondary shaft rear bearing using the SSTs.

## Secondary Shaft C Ring Assembly Note

1. Install the secondary shaft C ring to the secondary shaft.

2. Measure the clearance between the secondary shaft C ring and the secondary shaft rear bearing.

  • If not within the specification, adjust it by selecting a proper C ring from below.

Clearance

  0.00-0.06 mm {0.0000-0.0024 in}

Secondary shaft C ring size

Thickness (mm {in})
2.535 {0.0998} | 2.835 {0.1116}
2.565 {0.1010} | 2.865 {0.1128}
2.595 {0.1022} | 2.895 {0.1140}
2.625 {0.1033} | 2.925 {0.1152}
2.655 {0.1045} | 2.955 {0.1163}
2.685 {0.1057} | 2.985 {0.1175}
2.715 {0.1069} | 3.015 {0.1187}
2.745 {0.1081} | 3.045 {0.1199}
2.775 {0.1093} | 3.075 {0.1211}
2.805 {0.1104} | -

3. Inspect the 1st gear and 2nd gear end play. (See SECONDARY SHAFT COMPONENTS PREINSPECTION.)