Part 1

LEFT SIDE COVER
Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Cut the lock tabs of each shaft locknut using a chisel, then remove the locknuts and conical spring washers from each shaft.
- Countershaft locknut has left-hand threads.

1. Remove the Vehicle Speed Sensor (VSS) cover, then reinstall three bolts around the driveshaft oil seal.

CAUTION: Do not damage the driveshaft oil seal lip.

2. Slip the special tool onto the mainshaft, and engage the parking brake pawl with the parking gear.
3. Remove the transmission left side cover in the following numbered sequence.

NOTE: Remove the special tool from the mainshaft after removing the locknuts.

TRANSMISSION HOUSING
Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- The (7/32) #7 steel ball in the reverse idler gear shaft is under spring pressure. Take care not to let it pop out.

1. Remove the transmission housing in the following numbered sequence.

CAUTION: Set the special tool with bolts as shown.

VALVE BODY
Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Accumulator covers are spring loaded; to prevent stripping the threads in the torque converter housing, press down on the accumulator covers while unscrewing the bolts in a crisscross pattern.

1. Remove the valve body in the following numbered sequence.

CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.

Repair

NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. Use this procedure to free the valves.

1. Soak a sheet of #600 abrasive paper in ATF for about 30 minutes.
2. Carefully tap the valve body so the sticking valve drops out of its bore.

CAUTION: It may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver.

3. Inspect the valve for any scuff marks. Use the ATF soaked #600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air.

4. Roll up half a sheet of ATF-soaked paper and insert it in the valve bore of the sticking valve. Twist the paper slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and out.
5. Remove the #600 paper and thoroughly wash the entire valve body in solvent, then dry with compressed air.

6. Coat the valve with ATF, then drop it into its bore. It should drop to the bottom of the bore under its own weight. If not, repeat step 4 and 5, then retest. If the valves still sticks, replace the valve body.
7. Remove the valve, and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF as a lubricant.

VALVE
Assembly

NOTE: Coat all parts with ATF before assembly.

- Install the valve, valve spring and cap in the valve body, then install the roller.

- Set the spring in the valve, and install it in the valve body. Push the spring in with a screwdriver, then install the spring seat.

- Set the spring in the valve, and install it in the valve body. Install the spring with a screwdriver, then install the valve cap with the cutout aligned with the screwdriver.

- Install the valve, spring and cap in the valve body. Push on the cap, then install the stopper seat.

VALVE CAPS
Description
- Caps with one projected tip and one flat end are installed with the flat end toward the spring.

- Caps with a projected tip on each end are installed with the smaller tip toward the spring. The small tip is a spring guide.

- Caps with one projected tip and hollow end are installed with the tip toward the spring. The tip is a spring guide.
- Caps with hollow ends are installed with the hollow end away from the spring.
- Caps with notched ends are installed with the notch toward the spring.

- Caps with flat ends and a hole through the center are installed with the smaller hole toward the spring.

- Caps with flat ends and a groove around the cap are installed with the groove side opposite the spring.

ATF PUMP
Inspection

1. Install the pump gears and shaft in the main valve body.

2. Measure the side clearance of the drive and driven gears.

Pump Gears Side (Radial) Clearance:
Standard (New): Drive gear (diameter) 0.210-0.265 mm (0.0083-0.0104 inch)
Driven gear (radius) 0.035-0.063 mm (0.0014-0.0025 inch)

3. Remove the shaft, then measure the thrust clearance of the driven gear-to-valve body.

Drive/Driven Gear thrust (Axial) Clearance:
Standard (New): 0.03-0.05 mm (0.001 - 0.002 inch)
Service Limit: 0.07 mm (0.0028 inch)

MAIN VALVE BODY
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF before reassembly.
- Adjust and select the manual valve detent spring when the manual valve or manual valve detent spring is replaced.

CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.

NOTE: All check balls are the same size (7/32)#7.

SECONDARY VALVE BODY
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF before reassembly.

CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.

NOTE: All check balls are the same size (7/32) #7.

SERVO BODY/THROTTLE VALVE BODY
Disassembly/Inspection/Reassembly

NOTE:
- After disassembly of the ATF strainer, check that it is in good condition, and the inlet opening is not clogged. Replace the strainer with a new one if it is clogged or damaged.
- The strainer can be reused if it is not clogged. Clean the inlet opening thoroughly with compressed air before reinstalling it.

REGULATOR VALVE BODY
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.

1. Hold the regulator spring cap in place while removing the lock bolt. Once the bolt is removed, release the spring cap slowly.

CAUTION: The regulator spring cap can pop out when the lock bolt is removed.

2. Reassembly is the reverse of the disassembly procedure.

NOTE:
- Coat all parts with ATF.
- Align the hole in the regulator spring cap with the hole in the valve body, press the spring cap into the body and tighten the lock bolt.

Regulator Valve Body:

Spring Specifications

LOCK-UP VALVE BODY
Disassembly/Inspection/Reassembly

NOTE:
- Lubricate all parts with ATF during reassembly.
- Install thrust needle bearings with unrolled edge of bearing retainer facing washer.
- Inspect thrust needle and needle bearings for galling and rough movement. Locknut has left-hand threads.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

CAUTION: Before installing the '1st-hold clutch O-rings, install the 1st gear collar and thrust washer.

Inspection/Installation

NOTE: Lubricate all parts with ATF during assembly.

1. Assemble the parts below on the countershaft.

NOTE: Do not install the O-rings during inspection.

2. Hold the 2nd gear against the 3rd gear. Measure the clearance between the 3rd gear and thrust needle bearing with a feeler gauge.

NOTE: Take measurements in at least three places, and take the average as the actual clearance.

STANDARD: 0-0.03 mm (0-0.001 inch)

3. If the clearance is out of tolerance;
a. Select and install a new 3rd gear collar, and recheck the clearance.
b. If the clearance is still out of tolerance, replace the two thrust needle bearings, and recheck the clearance.

NOTE:
- If the clearance still exceeds the service limit even with new thrust needle bearings, check the 3rd gear, 2nd gear and 3rd gear collar for wear, and replace any worn parts.
- After replacing parts, make sure that the clearance is within tolerance.

4. Hold the 2nd gear against the 3rd gear. Measure the clearance between the 2nd gear spacer and cotters with a feeler gauge.

NOTE: Take measurements in at least three places, and take the average as the actual clearance.

STANDARD: 0-0.05 mm (0-0.002 inch)

5. If the clearance is out of tolerance, select and install a new cotters.
6. After replacing the cotters, make sure that the clearance is held within tolerance.
7. Remove the countershaft bearing from the transmission housing.
8. Assemble the countershaft including all bearings and other parts.

9. Torque the countershaft locknut to 29 Nm (3.0 kgf-m, 22 ft.lbs.).

10. Measure the clearance between 4th gear and reverse selector hub with a feeler gauge.

NOTE: Take measurements in at least three places, and take the average as the actual clearance.

STANDARD: 0.05 - 0.11 mm (0.002 - 0.004 inch)

11. If the clearance is out of tolerance, select and install a new cotter retainer.

Cotter Retainer

12. After replacing the cotter retainer, make sure that the clearance is within tolerance.

13. Measure the clearance between 1st gear and 1st hold clutch hub with a feeler gauge.

NOTE: Take measurements in at least three places, and take the average as the actual clearance.

STANDARD: 0.20 - 0.31 mm (0.008 - 0.012 inch)

14. If the clearance is out of tolerance, select and install a new 1st gear collar.

1st Gear Collar

15. After replacing the 1st gear collar, make sure that the clearance is within tolerance.

ONE-WAY CLUTCH/PARKING GEAR
Disassembly/Inspection/Reassembly

1. Separate countershaft 1st gear from the parking gear by turning the parking gear in the direction shown.

One-way Clutch/Parking Gear:

2. Remove the one-way clutch by prying it up with the end of a screwdriver.

Inspect the parts as follows:

3. After the parts are assembled, hold countershaft 1st gear and turn the parking gear in the direction shown to be sure it turns freely.

SECONDARY SHAFT
Disassembly/Inspection/Reassembly

NOTE:
- Lubricate all parts with ATF during reassembly.
- Install thrust needle bearings with unrolled edge of bearing retainer facing washer.
- Inspect thrust needle and needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

Inspection/Installation

NOTE:
- Lubricate all parts with ATF during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

1. Assemble the parts below on the secondary shaft.

NOTE:
- Install the thrust washer so that the large chamfer on the circumference faces the 2nd clutch assembly.
- Do not install the O-rings during inspection.

2. Hold the 2nd clutch assembly against the 3rd gear. Measure the clearance between the 2nd gear and thrust needle bearing using a feeler gauge.

NOTE: Take measurements in at least three places, and take the average as the actual clearance.

STANDARD: 0.01 - 0.07 mm (0.0004 - 0.0028 inch)

3. If the clearance is out of tolerance, select and install a new thrust washer.
4. After replacing the thrust washer, make sure that the clearance is within tolerance.