Part 2 of 2

Intermediary Shaft 4th Gear Removal

1. Place the 4th gear (A) on press bases (B), and place a shaft protector (C) between the Intermediary shaft (D) and a press to prevent damaging the Intermediary shaft.
2. Press the Intermediary shaft out of press-fitted 4th gear, and remove the Intermediary shaft while holding the underside the Intermediary shaft. The Intermediary shaft falls down when pressing the Intermediary shaft out of the press-fitted gear.
3. Remove the remaining parts from the Intermediary shaft.

Intermediary Shaft 4th Gear Installation

Special Tools Required
- Driver, 40 mm I.D. 07746-0030100

1. Wrap the shaft splines with tape, and install the new O-rings in the 3rd clutch O-ring grooves, then remove the tape.
2. Install the 3rd clutch, 53 mm splined washer, thrust needle bearing, needle bearing, 3rd gear, thrust needle bearing on the Intermediary shaft.

3. Install the 4th gear (A) with the special tool and a press.
4. Install the 19.8 mm cotters, cotter retainer, and snap ring.
5. Install the 26.5 mm washer on the top of the Intermediary shaft.

Intermediary Shaft 3rd Gear Clearance Inspection

Special Tools Required
- Driver, 40 mm I.D. 07746-0030100

1. Install the 3rd clutch (A), 53 mm splined washer {B), thrust needle bearing (C), needle bearing (D), 3rd gear (E), and thrust needle bearing (F) on the Intermediary shaft (G). Do not install the O-rings during inspection.

2. Install the 4th gear (H) with the special tool and a press.
3. Install the cotters (I), cotter retainer (J), and snap ring (K).

4. Set the dial indicator (A) on the 4th gear (B).

5. Measure the 4th gear axial clearance in at least three places while moving the 4th gear. Use the average as the actual clearance.
6. If the measurement is out of standard, remove the splined washer and measure its thickness.
7. Select and install a new splined washer, then recheck the clearance.

SPLINED WASHER, 53 mm

Intermediary Shaft Installation Height Inspection/Adjustment

1. Install the intermediary shaft (A) in the torque converter housing, and install the 26.5 mm washer (B) on the intermediary shaft.
2. Install the new gasket (C) on the torque converter housing.

3. Measure the height (D) of the intermediary shaft installation between the surface (E) of the gasket and the surface of the 26.5 mm washer (F).
4. If the measurement is out of standard, remove the 26.5 mm washer and measure its thickness.

5. Select and install a new washer, then recheck the installation height.

Clutch Disassembly

Special Tools Required
- Clutch spring compressor attachment 07LAE-PX40100
- Clutch spring compressor attachment 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Remove the snap ring (A), then remove the clutch end plate, the clutch discs, and the plates with a screwdriver (B).

2. Remove the disc spring (A) from the 1st and 3rd clutches.

NOTE: The disc springs of the 2nd and 1st-hold clutches are crimped on the clutch piston; the disc springs are undetached from the piston.

3. Remove the waved spring (A) from the 4th and 5th clutches.

4. Install the special tools on the clutch assembly.

5. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 2nd, 4th and 5th clutches.

6. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.

7. Set the special tool (A) on the spring retainer (B) of the 3rd clutch so the tool works on the clutch return spring (C).

8. If either end of the special tool is not set over the clutch return spring and (A), the retainer may be damaged.

9. Compress the spring until the snap ring can be removed.

10. Remove the snap ring (A). Then remove the special tool (B), spring retainer (C), and the return spring.

11. Wrap the shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.

Clutch Inspection
1st/1st-hold Clutch

1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or stuck damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
- If the clutch discs are worn or damaged, replace the discs as a set.
- If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
- If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.

Clutch Reassembly

Special Tools Required
- Clutch spring compressor attachment 07LAE-PX40100
- Clutch spring compressor attachment 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
- Clutch compressor attachment 07ZAE-PRP0100

Note these items during reassembly:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow all passages.
- Apply ATF to all parts before assembly.

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.

2. Install the new O-rings (A) on the clutch piston (B).

3. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.
4. Check the 1st-hold clutch end-plate-to-top-disc clearance; starting with a clutch plate, alternately install the clutch plate and discs in the 1st-hold clutch drum, then install the 1st-hold clutch plate B.

5. Measure the 1st-hold clutch clearance between the 1st-hold clutch plate B and the top disc (A) with a feeler gauge (C) while pressing the 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.
6. If the clearance is out of standard, replace the 1sthold clutch plates and discs as a set, and recheck.

7. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.

8. Install the special tool on the clutch assembly.

9. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 2nd, 4th and 5th clutches.

10. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.

11. Set the special tool (A) on the spring retainer (B) of the 3rd clutch so the tool works on the clutch return spring (C).

12. If either end of the special tool is not set over the clutch return spring end (A), the retainer may be damaged.

13. Compress the return spring.

14. Install the snap ring (A).

16. Install the disc spring in the 1st and 3rd clutches in the direction shown.

NOTE: The disc springs of the 2nd and 1st-hold clutches are crimped on the clutch piston; the disc springs are undetached from the piston.

17. Install the waved spring in the 4th and 5th clutches.
18. Make sure the inside of the clutch drum is free of dirt and other foreign particles.

19. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate (A) with the flat side toward the disc (B).

20. Install the snap ring (A) with a screwdriver (B).

21. Set a dial indicator (A) on the clutch end plate (B).
22. Zero the indicator with the clutch end plate lifted up to the snap ring (C).

23. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
24. Press the special tool down with 39 N (4 kgf, 9 lbs) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use average as the actual clearance.
Clutch End-Plate-to-Top-Disc Clearance Service Limit:
1st clutch: 1.1 - 1.3 mm (0.043 - 0.051 inch)
2nd clutch: 1.0 - 1.2 mm (0.039 - 0.047 inch)
3rd clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
4th clutch: 0.55 - 0.75 mm (0.02 - 0.030 inch)
5th clutch: 0.55 - 0.75 mm (0.022 - 0.030 inch)

25. If the clearance is out of service limit, select a new clutch end plate from the tables. Install the new clutch end plate, then recheck the clearance.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.

1ST CLUTCH END PLATES

2ND CLUTCH END PLATES

3RD CLUTCH END PLATES

4TH and 5TH CLUTCH END PLATES