2. Automatic Transmission Reassembly

Automatic Transmission Reassembly

Exploded View





Special Tools Required

- Mainshaft Holder Set 07PAB-0010001

1. Make sure that the ATF magnet is cleaned and installed in the torque converter housing. Clean and install the ATF magnet, if necessary.

2. Install the 2nd air check valve and the 5th air check valve in the torque converter housing.

3. Install the main separator plate and the two dowel pins on the torque converter housing. Then install the ATF pump drive gear (A), the driven gear (B), and the ATF pump driven gear shaft (C). Install the ATF pump driven gear with its grooved and chamfered side facing down.






4. Install the main valve body (eight bolts). Make sure the ATF pump drive gear (A) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (B) moves smoothly in the axial and normal operating direction.






5. If the ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torques, then recheck. Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft.

6. Install the two check balls in the main valve body.

7. Install the regulator separator plate and the two dowel pins on the main valve body, and install the regulator valve body (eight bolts).

8. Install the manual separator plate and the two dowel pins on the main valve body, and install the manual valve body (seven bolts).

9. Install the 4th/reverse air check valve in the main valve body.

10. Install the two dowel pins on the main valve body.

11. Install the stator shaft with new O-rings (three), and install the stator shaft support (four bolts).

12. Install the 3rd air check valve and the 6th air check valve in the stator shaft support.

13. Install the stator shaft stop in the torque converter housing.

14. Install the cooler retainer cap.

15. Install the transfer output shaft (A) in the torque converter housing, and install the thrust shim (B) on the top of the transfer output shaft.





16. Install the differential assembly (C) in the torque converter housing.

17. Install the third shaft (D) into the main valve body.

18. Install the selector control shaft (E).

19. Align the control lever pin (A) with the manual valve guide (B).






20. Hook the detent spring (A) to the detent arm (B) and the selector control shaft (C), then install the detent arm and the detent arm shaft (D) into the torque converter housing.






21. Install the parking holder (A).





22. Assemble the mainshaft, the countershaft, the secondary shaft and the idler gear shaft.

23. Install the thrust needle bearing (A) on the secondary shaft bearing in the torque converter housing.





24. Join the mainshaft subassembly (B), the countershaft subassembly (C), the secondary shaft subassembly (D), and the idler gear shaft subassembly (E) together, and install them in the torque converter housing. Install the 27.5 x 41 x 2.5 mm thrust needle bearing (F) and the 41.5 mm washer (G) on the top of the idler gear shaft.

25. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole of the shift fork.






26. Install the baffle plate (B), the shift fork (C), the reverse selector hub (D), and the reverse gear (E) together.

27. Secure the shift fork (A) to the shift fork shaft with the lock bolt and a new lock washer (B), then bend the lock tab of the lock washer against the bolt head.






28. Install the lubrication pipe (A) and the 10 x 70 mm ATF feed pipe (B) into the regulator valve body (C).





29. Install the ATF strainer (D) with a new O-ring.

30. Install new O-rings (A) (four) on the joint pipes (B) (two), and install the joint pipes into the manual valve body (C) and the torque converter housing (D).






31. Install the two dowel pins (A) and a new gasket (B) on the torque converter housing (C).





32. Install transmission hanger A (D) and transmission hanger B (E) in the transmission housing (F), then place the transmission housing on the torque converter housing.

33. Wrap a screwdriver tip with tape to prevent damage to the reverse idler gear teeth. Engage the reverse idler gear with the reverse gears by rotating the idler gear using a screwdriver.






34. While expanding the snap ring of the countershaft bearing using snap ring pliers, install the transmission housing onto the bearing part-way. Then release snap ring pliers, and push down on the transmission housing until it bottoms and snap ring snaps into place in the countershaft bearing snap ring groove.






35. Install the transmission housing mounting bolts along with transmission hanger C, and tighten the bolts in at least two steps in a criss-cross pattern to the specified torque.






36. Install the mainshaft holder onto the mainshaft.






37. With a 6.0 mm wrench, turn the selector control shaft fully counterclockwise (viewed from the shaft end) to the P position.






38. Install new lock washers (A) with the marked side (B) up over the mainshaft (C), and the third shaft (D), and apply ATF to surfaces of the lock washers and the old locknuts (E).





39. Install old locknuts, and tighten them to seat the lock washers to the specified torque, then remove the old locknuts.

NOTE: The third shaft locknut has left-hand threads.

40. Install new locknuts, and tighten them to the specified torque, then stake the locknuts to a depth (A) of 0.7-1.3 mm (0.03-0.05 in) using a 3.5 mm punch (B).






41. Install a new O-ring (A) on the mainshaft end cover (B), and install the mainshaft end cover. Install a new O-ring (C) on the third shaft end cover (D), and install the third shaft end cover and the ATF filter bracket (E).





42. Install new O-rings (F) on the end covers (G), and install the end covers.

43. Apply ATF to new O-rings (A), and install the O-rings over the ATF pipes (B). Then install the ATF pipes with the filter ends (C) facing the secondary valve body (D) into the transmission (E).





44. Install a new gasket (F) on the transmission housing. Install the secondary valve body while aligning the ATF pipes with the pipe holes on the secondary valve body, and secure the valve body with the bolts.

45. Install new O-rings (A) on the shift solenoid valve (B), and install the shift solenoid valve C.





46. Install transmission fluid pressure switch C (4th clutch) (C) with a new sealing washer (D). Tighten the switch by gripping the metal part, not the plastic part.

47. Install transmission fluid pressure switch A (2nd clutch) (A) with a new sealing washer (B). Tighten the switch by gripping the metal part, not the plastic part.





48. Install transmission fluid pressure switch D (5th clutch) (C) with a new sealing washer (D). Tighten the switch by gripping the metal part, not the plastic part.

49. Install the ATF outlet line (A) on the torque converter housing, and secure it with the banjo bolt (B) and new sealing washers (C), then secure the ATF outlet line with the bracket bolt.





50. Install the ATF inlet line/ATF hose/ATF filter (D) on the torque converter housing, and secure it with the banjo bolt (E) and new sealing washers (F), then secure the ATF inlet line with the bracket bolt.

51. Put the ATF filter (G) on ATF filter bracket (H), and secure it with the ATF filter holder (I) and the bolt.

52. Install a new O-ring (A) on the ATF temperature sensor (B), and install the ATF temperature sensor.






53. Install a new O-ring (A) on the input shaft (mainshaft) speed sensor (B), and install the input shaft (mainshaft) speed sensor.





54. Install a new O-ring (C) on the output shaft (countershaft) speed sensor (D), and install the output shaft (countershaft) speed sensor.

55. Install the control lever (A) over the selector control shaft (B). Secure the control lever with the new lock washer (C) and the bolt, then bend the lock tab of the lock washer against the bolt head.






56. Shift the transmission in the N position by rotating the control lever. Do not use the control shaft to adjust the shift position. If the selector control shaft tips are squeezed together, it will cause a faulty signal or position due to play between the control shaft and the transmission range switch.






57. Align the cutouts (A) on the rotary-frame with the N positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 in) feeler gauge blade (D) in the cutouts to hold the switch in the N position.

NOTE: Be sure to use a 2.0 mm (0.08 in) blade or equivalent to hold the switch in the N position.






58. Install the transmission range switch (A) gently on the selector control shaft while holding it in the N position with the 2.0 mm (0.08 in) blade (B).





59. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge.

60. Install the ATF dipstick guide tubes (A) with new O-rings (B).





61. Install the ATF dipstick (C) in the guide tube.