Assembly

NOTE:
* Coat all parts with ATF.
* Replace the following parts:
- O-rings
- Lock washers
- Gaskets
- Mainshaft and countershaft locknuts and conical disc springs
- Sealing washers
* TORQUE:
6 x 1.0 mm Bolts: 12 Nm (8.7 ft. lbs.).
8 x 1.25 mm Bolts: 18 Nm (13 ft. lbs.).
5 x 0.8 mm Flange nuts: 6 Nm (4 ft. lbs.).

1. Install the linear solenoid harness and linear solenoid harness connector into the torque converter housing.
2. Install the ATF pump body separator plate and three dowel pins on the torque converter housing.

CAUTION: Take care not to pinch the linear solenoid harness.





3. Install the ATF pump drive gear, ATF pump driven gear, ATF pump driven gear shaft, torque converter check valve, and spring on the torque converter housing.

NOTE: Install the ATF pump driven gear with its grooved and chamfered side facing down.

4. Install the ATF pump body with three 8 mm bolts and two 6 mm bolts. Make sure the ATF pump drive gear rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft moves smoothly in the axial and normal operating directions.





5. If the ATF pump drive gear and ATF pump driven gear shaft do not move freely, loosen the ATF pump body bolts, realign the ATF pump driven gear shaft, and then retighten to the specified torque.

CAUTION: Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump driven gear or ATF pump driven gear shaft.

6. Install the throttle valve body/linear solenoid on the 2nd accumulator body with two dowel pins, throttle valve body separator plate, and harness clamp (four bolts).
7. Install the 2nd accumulator piston and 2nd accumulator spring in the 2nd accumulator body, then install the 2nd accumulator body on the torque converter housing (six bolts).
8. Install the regulator separator plate on the ATF pump body with two dowel pins.
9. Install the stator shaft with a new O-ring and stopper shaft.
10. Install the regulator valve body (nine bolts).
11. Connect the linear solenoid harness to the linear solenoid terminal, then tighten the two flange nuts to 6 Nm (4 ft. lbs.).
12. Tighten the linear solenoid harness connector bolt to 8 Nm (6 ft. lbs.).
13. Install the ATF feed pipe in the ATF pump body, the two ATF feed pipes in the torque converter housing, and the two ATF feed pipes in the 2nd accumulator body.





14. Install the reverse idler gear and reverse idler gear shaft assembly in the transmission housing.
15. Assemble the mainshaft sub-assembly.
16. Assemble the countershaft sub-assembly.
17. Install the secondary driven gear shaft in the torque converter housing.





18. Install the mainshaft sub-assembly and the countershaft sub-assembly together in the torque converter housing.
19. Install three dowel pins and a new gasket on the torque converter housing.
20. Place the transmission housing on the torque converter housing.

CAUTION: Make sure that the mainshaft and countershaft speed sensors are not installed on the transmission housing before installing the transmission housing on the torque converter housing.





21. Install the transmission housing mounting bolts, and torque them in two or more steps in the sequence shown.
22. Install the 10 mm bolt and three 8 mm bolts to the transmission housing from the torque converter housing side, and torque them.
23. Install the mainshaft and countershaft speed sensors on the transmission housing
24. Install the connector brackets and connector holder on the transmission housing.





25. Install the parking brake pawl, spring, pawl shaft and stopper shaft on the transmission housing.
26. Shift to any gear other than the P position by turning the control shaft or the detent lever.
27. Install the parking gear, countershaft 1st gear collar and needle bearings on the countershaft.
28. Assemble the one-way clutch in the countershaft 1st gear, then install them on the countershaft.
29. Install the mainshaft 1st gear collar and the thrust washer on the mainshaft.
30. Install the O-ring on the mainshaft and countershaft.

NOTE: Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

31. Install the thrust washer, thrust needle bearing, needle bearing and mainshaft 1st gear in the 1st clutch assembly, then install them on the mainshaft.
32. Install the thrust washer, thrust needle bearing and 1st-hold clutch hub in the 1st clutch assembly, then install them on the countershaft.





33. Install the special tool onto the mainshaft as shown.
34. Engage the parking brake pawl with the parking gear by turning the detent lever to the P position.
35. Coat new conical spring washers with ATF, then install them and new locknuts on each shaft.

CAUTION: Install the conical spring washers in the direction shown.





36. Tighten the locknuts to specified torque using a torque wrench.
* TORQUE: 137 Nm (101 ft. lbs.).

NOTE: The mainshaft locknut has left-hand threads.





37. Stake each locknut into its shaft using a 3.5 mm (0.14 inch) punch.
38. Assemble the lower valve body assembly.
39. Install the two dowel pins on the lower valve body assembly.
40. Push the shift fork toward the servo valve body.





41. Install the lower valve body assembly putting the manual valve and detent lever together, the reverse selector and the shift fork together, and joining the ATF feed pipes with the ATF feed pipe holes of the transmission housing.





42. Install the six bolts and torque as shown.
* TORQUE: 12 Nm (8.7 ft. lbs.).
43. Install the main valve body plate (four bolts).
44. Pass the shift control solenoid valve harness through the transmission housing, then install the shift control solenoid valve harness connector (one bolt).
45. Install the harness cover (four bolts).





46. Lightly pull the shift control solenoid valve harness from the harness cover, then bring the shift control solenoid valve harness back. Make sure that the shift control solenoid valve harness is not pinched. If the shift control solenoid valve harness is pinched, loosen the four bolts securing the harness cover then retighten the bolts.
* TORQUE: 12 Nm (8.7 ft. lbs.).





47. Install the ATF strainer with a new O-ring (four bolts).
* TORQUE: 12 Nm (8.7 ft. lbs.).





48. Install the ATF pan with two dowel pins and a new gasket (fifteen bolts) as shown. Make sure that the shift control solenoid valve harness is not pinched by the ATF pan.
* TORQUE: 12 Nm (8.7 ft. lbs.).
49. Install four ATF feed pipes in the transmission housing.
50. Install the rear cover with two dowel pins and a new gasket (eight bolts).





51. Install the A/T gear position switch harness clamp on the rear cover.





52. Install the A/T gear position switch cover. Tighten the bolt on the ATF pan side loosely so that there is no clearance between the A/T gear position switch cover and the ATF pan. Then tighten the bolt on the rear side cover side to the specified torque, and tighten the bolt on the ATF pan side to the specified torque.





53. Install the ATF cooler pipes on the transmission housing, if necessary.
54. Install the ATF dipstick.
55. Connect the connectors, and install them on the connector brackets and connector holder.