2. Transmission Housing Disassemble & Service
Housing and Shaft Assembly RemovalSpecial Tools Required
Housing puller 07HAC-PK40102
1. Remove the ATF dipstick guide pipe (A).
2. Remove the two bolts securing the reverse idler gear shaft holder, then remove the reverse idler gear shaft holder (B) and shaft (C).
3. Remove the transmission housing mounting bolts (17 bolts), transmission hangers (D) (E), and harness clamp bracket (F).
4. Move the reverse idler gear (G) to disengage it from the mainshaft and countershaft idler gear.
NOTE: The transmission housing will not separate from the torque converter housing if the reverse idler gear is not moved.
5. Align the spring pin (W) on the control shaft (X) with the transmission housing groove (Y) by turning the control shaft.
6. Install the special tool over the mainshaft, then remove the transmission housing (H),
NOTE: If the top arm of your housing puller is too short, replace it with Housing Puller Arm, 205 mm T/N 07SAC-P0Z0101.
7. Remove the reverse idler gear (G), needle bearings, and washers from the transmission housing.
8. Remove the output shaft (countershaft) speed sensor (I).
9. Remove the three dowel pins (J) and gasket (K) from the torque converter housing (L).
10. Remove the countershaft 2nd gear (M), countershaft reverse gear (N), and needle bearing (O).
11. Remove the lock bolt securing the shift fork, then remove the shift fork (P) and reverse selector (Q), If the reverse selector hub is not press-fitted, remove the reverse selector hub, countershaft 5th gear, and needle bearing from the countershaft.
12. Remove the secondary shaft subassembly (R). If the reverse selector hub is press-fitted, remove the secondary shaft subassembly, countershaft subassembly (S) and mainshaft subassembly (T) together.
13. Remove the countershaft subassembly.
14. Remove the mainshaft subassembly.
15. Remove the differential assembly (U).
16. Remove the ATF magnet (V), and clean it. Reinstall the magnet in the transmission housing.
Bearing Removal and Installation
Special Tools Required
- Driver 07749-0010000
- Seal driver attachment 07GAD-PG40101 or 07GAD-PG40100
- Attachment, 72 x 75 mm 07746-0010600
NOTE: Coat all parts with ATF before assembly.
1. To remove the mainshaft bearing (A), countershaft bearing (B), and secondary shaft bearing (C) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out.
NOTE: Do not remove the snap rings unless it is necessary to clean the grooves in the housing.
2. Install the mainshaft bearing (A), countershaft bearing (B), and secondary shaft bearing (C) in the direction shown.
3. Expand each snap ring with the snap ring pliers, and insert the bearing part-way into the housing.
4. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
5. After installing the bearings verify that the snap rings (A) are seated in the bearing and housing grooves, and that the ring end gaps (B) are correct.
Shaft Assembly and Housing Installation
1. Install the differential assembly (A) in the torque converter housing (B).
2. If the reverse selector hub is press-fitted type, join the mainshaft (C), countershaft (D), and secondary shaft (E) together, then install them in the torque converter housing.
3. If the reverse selector hub in not press-fitted type, install the countershaft, mainshaft, and secondary shaft in the torque converter housing, then install the countershaft 5th gear and reverse selector hub on the countershaft.
4. Turn the shift fork shaft so the large chamfered hole is facing the fork bolt hole.
5. Install the shift fork (F) and reverse selector (G) together on the shift fork shaft and countershaft (D). Install the reverse selector in the direction shown.
6. Secure the shift fork to the shift fork shaft with the lock bolt and a new lock washer (H), then bend the lock washer against the lock bolt head.
7. Install the needle bearing (I), countershaft reverse gear (J), and countershaft 2nd gear (K) on the countershaft.
8. Place the thrust washer (L) in the transmission housing.
9. Place the reverse idler gear (M) in the transmission housing, and slide it in the direction shown.
10. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C) by turning the control shaft.
11. Install three dowel pins (D) and a new gasket (E) on the torque converter housing (F).
12. Place the transmission housing (G) on the torque converter housing, then install the transmission housing mounting bolts along with the harness clamp bracket (H) and transmission hangers (I).
13. Tighten the 13 mounting bolts (J) to 44 Nm (4.5 kgf-m, 33 ft. lbs.) in two or more steps in a crisscross pattern, and tighten the four bolts (K) to 48 Nm (4.9 kgf-m, 35 ft. lbs.).
14. Install the new O-ring on the output s haft (countershaft) speed sensor (L), then install it in the transmission housing.
15. Engage the reverse idler gear with the countershaft reverse gear and mainshaft reverse gear. Then install the needle bearings (A), reverse idler gear shaft (B), and thrust washer (C) in the reverse idler gear, and install the reverse idler gear shaft holder (D) on the transmission housing.