Reassembly
Reassembly
NOTE:
- Clean all parts with ATF.
- Replace the following parts:
- Lock washers and sealing washers
- O-rings
- Gaskets
- locknuts and conical spring washers
1. Install the suction pipe collar and ATF magnet in the torque converter housing, if necessary.
2. Install the main separator plate and the two dowel pins on the torque converter housing.
3. Install the ATF pump drive gear, ATF pump driven gear, and ATF pump driven gear shaft on the torque converter housing. Install the ATF pump driven gear with its grooved and chamfered side facing down.
4. Loosely install the main valve body with five 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. Install the secondary valve body, separator plate, and two dowel pins on the main valve body. Do not install the bolts.
6. Install the control shaft in the housing along with the manual valve.
7. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm.
8. Install the servo body and separator plate on the secondary valve body (eight bolts).
9. Install the ATF strainer (one bolt).
10. Tighten the five bolts on the main valve body to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.).
11. Make sure the ATF pump drive gear and ATF pump driven gear shaft move smoothly. If they don't, loosen the bolts on the main valve body, and disassemble the valve bodies. Realign the ATF pump driven gear shaft and reassemble the valve bodies, then retighten the bolts to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.).
CAUTION: 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.
12. Install the stator shaft and stop shaft.
13. Install the bolts and the stop shaft bracket on the secondary valve body, then tighten the bolts (three bolts).
14. Install the torque converter check valve, cooler relief valve, and valve springs in the regulator valve body, then install the regulator valve body on the main valve body (one bolt).
15. Install the lock-up valve body, separator plate, two dowel pins and lubrication plate (eight bolts).
16. Install the one ATF feed pipe in the main valve body, the three ATF feed pipes in the secondary valve, the three ATF feed pipes in the servo body and the one ATF feed pipe in the lock-up valve body.
NOTE: Install the 105.8 mm ATF feed pipe with its filter side away from the secondary valve body.
17. Install the sub-shaft assembly in the transmission housing.
18. Install the reverse idler gear and gear shaft holder.
19. Install the differential assembly in the torque converter housing.
20. Assemble the mainshaft and countershaft subassembly, then install them together in the torque converter housing.
21. Turn the shift fork so the large chamfered hole is facing the fork bolt hole, then install the shift fork with the reverse selector and torque the lock bolt. Bend the lock tab against the bolt head.
22. Install the reverse gear with the collar and needle bearing on the countershaft.
23. Align the spring pin on the control shaft with the transmission housing groove by turning the control shaft.
24. Place the transmission housing on the torque converter housing with a new gasket and the three dowel pins.
Make sure that the mainshaft speed sensor is not installed on the transmission housing before installing the transmission housing on the torque converter housing.
25. Install the transmission housing mounting bolts along with the transmission hanger, then tighten the bolts in two or more steps in the sequence shown.
26. Install the mainshaft speed sensor (with new O-ring) and sensor washer on the transmission housing.
27. Install the park lever on the control shaft, then install the lock bolt with a new lock washer. Do not bend the lock tab of the lock washer in this step; bend it after checking the park pawl engagement in step 44.
28. Assemble the one-way clutch and the park gear on the countershaft 1st gear.
29. Lubricate these parts with ATF:
- Countershaft threads
- Old locknut threads and flat end
- Old conical spring washer
- Park gear contact area with conical spring washer
30. Install the countershaft list gear collar, needle bearing, and the countershaft 1st gear/park gear assembly on the countershaft.
31. Install the park pawl shaft, pawl spring, pawl, and pawl stop on the transmission housing, then engage the pawl with the park gear.
32. Install the old locknut and the old conical spring washer on the countershaft. Tighten the old locknut to seat the park gear to the specified torque, then remove the washer and locknut. The locknut has left-hand threads. Do not use an impact wrench. Always use a torque wrench to tighten the locknut.
33. Slip the special tool onto the mainshaft.
34. Install the sub-shaft 1st gear on the sub-shaft.
35. Install the mainshaft 1st gear collar, mainshaft 1st gear, needle bearing, thrust needle bearing, and the thrust washer on the mainshaft.
36. Wrap the shaft splines with tape to prevent O-ring damage, then install new O-rings on the mainshaft.
37. Install the 1st clutch assembly on the mainshaft.
38. Align the hole of the sub-shaft list gear with the hole of the transmission housing, then insert an 8 mm pin to hold the sub-shaft while tightening the sub-shaft locknut.
39. Install new conical spring washers and new locknuts on each shaft. Install the washers in the direction shown.
40. Tighten the locknuts to the specified torque. Mainshaft and countershaft locknuts have left-hand threads. Do not use an impact wrench. Always use a torque wrench to tighten the locknuts.
41. Stake each locknut using a 3.5 mm punch.
42. Set the park lever in P position, then verify that the park pawl engages the park gear.
43. If the pawl does not engage fully, check the distance between the park pawl shaft and the park lever roller pin.
44. Tighten the lock bolt and bend the lock tab.
45. Install the right side cover with two dowel pins and a new gasket (13 bolts).
46. Install the cooler lines with the line bolts and new sealing washers.
TORQUE: 28 Nm (2.9 kgf-m, 21 ft. lbs.)
47. Install the ATF dipstick.