Part 1
Shafts and ClutchesMainshaft Disassembly, Inspection, and Reassembly
1. Remove the thrust needle bearing (A), the mainshaft 5th gear (B), the needle bearing (C), the thrust needle bearing (D), the mainshaft 5th gear collar (E), the 4th/5th clutch (F), and the O-rings (G) from the mainshaft (H).
2. Inspect the condition of the sealing rings (I). If the sealing rings are worn, distorted, or damaged, remove the set ring (J) and the needle bearing (K), and replace the sealing rings with new ones.
3. Inspect the thrust needle bearing and the needle bearing for wear and rough movement.
4. Inspect the splines for excessive wear and damage.
5. Inspect 4th gear for wear and damage, and inspect the 4th gear bearing for wear and rough rotation.
6. Replace the mainshaft 4th gear (L) if 4th gear is worn or damaged, or the bearing is worn or damaged.
7. Check the shaft bearing surfaces for scoring and excessive wear.
8. Lubricate all parts with ATF during reassembly.
9. Wrap the shaft splines with tape to prevent O-ring damage, install new O-rings on the mainshaft, then remove the tape.
10. Install the 4th/5th clutch.
11. Install the mainshaft 5th gear collar, the thrust needle bearing, the needle bearing, the mainshaft 5th gear, and the thrust needle bearing.
Mainshaft 4th Gear Replacement
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Remove the mainshaft 4th gear (A) with a press. Place a shaft protector (B) between the press and the mainshaft (C) to prevent damaging the mainshaft.
2. Slide a new mainshaft 4th gear (A) over the mainshaft (B), then press it into place using the driver, 40 mm and a press.
Countershaft Disassembly
Countershaft:
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Cut the lock tab (A) of the countershaft locknut (B) using a chisel (C).
NOTE: Keep all of the chiseled particles out of the countershaft.
2. Hold the countershaft securely using a wrench and a vise, loosen the locknut, and remove it. The locknut has left-hand threads.
3. Place the countershaft 5th gear (A) an press bases (B), and place a shaft protector (C) between the countershaft (D) and a press to prevent damaging the countershaft.
4. Support the bottom of the countershaft with one hand, then press the countershaft out of the press-fitted bearing (E) and the press-fitted reverse selector hub. The countershaft will drop down after pressing it out of the press-fitted reverse selector hub. Some reverse selector hubs are not press-fitted, and the countershaft will drop down after pressing it out of the press-fitted bearing.
5. Remove the remaining parts from the countershaft.
6. Inspect the bearing for galling and rough movement.
7. Check the shaft bearing surfaces for scoring and excessive wear, and check the shaft splines for excessive wear and damage.
NOTE: If the countershaft is worn or damaged, replace the countershaft with the same letter (A, B, or C) for identification as the identifying letter on the final driven gear.
8. Check the idler gear axial clearance and the 4th gear axial clearance.
Countershaft Idler Gear and 4th Gear Axial Clearance Inspection
1. Install the 40.5 mm cotters; (A), 2nd gear (B), the thrust needle bearing (C), the needle bearing (D), the idler gear (E), the thrust needle bearing (F), the 61 mm washer (G), 1st gear (H), 4th gear (I), the 50.8 mm collar (J) the 50.8 mm washer (K), the 42.2 mm cotters (L), the cotter retainer (M), and the snap ring (N) on the countershaft (O). Install the 40.5 mm cotters, the idler gear, 1st gear, and 4th gear in the direction shown.
2. Insert a feeler gauge blade (A) as-thick as possible between the 50.8 mm collar (B) and the 50.8 mm washer (C).
3. Set the dial indicator (A) on the idler gear (B).
4. Measure the idler gear axial clearance in at least three places while moving the idler gear. Use the average as the actual clearance.
5. If the clearance is out of standard, remove the61 mm washer and measure its thickness.
6. Select and install a new washer, then recheck the clearance.
7. Measure the clearance between the 50.8 mm collar (A) and the 50.8 mm washer (B) using a feeler gauge (C) in at least three places. Use the average as the actual clearance.
8. If the clearance is out of standard, remove the 50.8 mm washer and measure its thickness.
9. Select and install a new washer, then recheck the clearance.
Countershaft Reassembly
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Install the 40.5 mm cotters (A), 2nd gear (B), the thrust needle bearing (C), the needle bearing (D), the idler gear (E), the thrust needle bearing (F), the 61 mm washer (G), 1st gear (H), 4th gear (I), the 50.8 mm collar (J) the 50.8 mm washer (K), the 42.2 mm cotters (L), the cotter retainer (M), and the snap ring (N) on the countershaft (O). Install the 40.5 mm cotters, the idler gear, 1st gear, and 4th gear in the direction shown.
2. Install the thrust washer (P), the needle bearing (Q), and 5th gear (R).
3. Slide the reverse selector hub (A) over the countershaft (B), then press it into place using the driver, 40 mm and the press.
NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the driver, 40 mm and a press.
4. Install the reverse selector, the reverse gear collar, the needle bearing, and the reverse gear over the reverse selector hub.
5. Install the ball bearing (A) over the countershaft, then press it into place using the driver, 40 mm and a press.
6. Install a new conical spring washer (A) in the direction shown, and install a new locknut (B).
7. Hold the countershaft securely using a wrench and a vise, and tighten the locknut to 167 N-m (17.0 kgf-m, 123 lbf-ft).
NOTE:
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ The locknut has left-hand threads.
8. Stake the locknut to a depth (A) of 0.7 - 1.3 mm (0.03 - 0.05 in.) using a 3.5 mm punch (B).
Secondary Shaft Disassembly
Secondary Shaft:
Special Tools Required
Wrench, 40 x 42 mm 07XAA-002010A
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Cut the lock tab (A) of the secondary shaft locknut (B) using a chisel (C).
NOTE: Keep all of the chiseled particles out of the secondary shaft.
2. Place a V-block (A) on the back of a vise (B), and clamp the wrench, 40 x 42 mm in the vise jaws (C).
3. Place the secondary shaft (D) on the block, and attach the 1st clutch guide (E) to the wrench, 40 x 42 mm. Loosen the locknut, and remove it. Remove any burrs from the splines on the shaft and the spline washer.
4. Place the idler gear (A) on press bases (B), and place a shaft protector (C) between the secondary shaft (D) and the press to prevent damaging the secondary shaft.
5. Support the secondary shaft with one hand, then press the secondary shaft out of the press-fitted bearing (E). The secondary shaft will drop down after pressing it out of the press-fitted bearing.
6. Remove the 1st/1st-hold clutch, the 52 mm washer, the thrust needle bearing, the 1st gear assembly, the needle bearing, the 1st gear collar, the thrust needle bearing, and the idler gear.
7. Remove the 32 mm snap ring, and remove the 2nd clutch, the splined washer, the thrust needle bearing, the needle bearing, the 2nd gear/park gear, and the thrust needle bearing.
8. Inspect the bearing for galling and rough movement.
9. Check the shaft bearing surfaces for scoring and excessive wear, and check the shift splines for excessive wear and damage.
10. Check the 1st gear axial clearance, the 1st gear one-way clutch, and the secondary shaft installation height.
Secondary Shaft 1st Gear Axial Clearance Inspection
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
1. Install the idler gear (A), the thrust needle bearing (B), the 1st gear collar (C), the needle bearing (D), the 1st gear assembly (E), the thrust needle bearing (F), the 52 mm washer (G), and the 1st/1st-hold clutch (H) on the secondary shaft (I). Install the idler gear and the 52 mm washer in the direction shown. Do not install the O-rings during inspection.
2. Install the ball bearing (J) over the 1st/1st-hold clutch guide using the driver, 40 mm, the attachment, 30 mm, and a press.
3. Install the splined washer (K) with the marked side (L) up over the ball bearing in the same manner as installing the ball bearing using the driver, 40 mm, the attachment, 30 mm, and a press.
4. Install the old lock nut (M) and tighten it to 29 N-m (3.0 kgf-m, 22 lbf-ft).
5. Set the dial indicator (A) on the 1st clutch hub (B).
6. Measure the 1st gear axial clearance in at least three places while moving 1st gear. Use the average as the actual clearance.
7. If the clearance is out of standard, remove the washer and measure its difference.
8. Select and install a new washer, then recheck the clearance.
1st Gear One-way Clutch Inspection
1. Hold the 1st-hold clutch hub (A), and turn 1st gear (B) in the direction shown to be sure it turns freely. Also make sure 1st gear locks in the opposite direction.
2. If any problem occurs on the 1st gear one-way clutch, replace the 1st clutch hub (C). The 1st gear one-way clutch is not available separately from the 1st clutch hub.
3. Also check 1st gear and the 1st-hold clutch hub for wear and damage. If 1st gear and the 1st-hold clutch hub are worn or damaged, replace the damaged part, refer to 1st Clutch Hub Replacement.
1st Clutch Hub Replacement
Special Tools Required
^ Driver 07749-0010000
^ Driver attachment 07947-6340500
^ Attachment, 78 x 90 mm 07GAD-SD40101
1. Remove the 1st-hold clutch hub (A) from 1st gear (B) using the driver and the driver attachment and a press.
2. Remove the 1st clutch hub (C) from 1st gear.
3. Install a new 1st clutch hub (A) over 1st gear (B),and install the 1st-hold clutch hub (C) in 1st gear.
NOTE: If 1st gear and the 1st-hold clutch hub are replaced, use 1st gear and the 1st-hold clutch hub with the same identifying letters (A or B).
4. Install the 1st-hold clutch hub (A) in 1st gear (B) using the driver and the attachment, 78 x 90 mm, and a press.
Secondary Shaft Reassembly
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
^ Wrench, 40 x 42 mm 07XAA-002010A
1. Install the thrust needle bearing (A), the needle bearings (B), the 2nd gear/park gear (C), the thrust needle bearing (D), and the splined washer (E) in the direction shown on the secondary shaft (F).
2. Wrap the shaft splines with tape, and install new O-rings (G) in the 2nd clutch O-ring grooves, then remove the tape.
NOTE: To prevent damaging the O-rings, be sure to install the O-rings after installing the splined washer.
3. Install the 2nd clutch (H) on the secondary shaft, and secure the 2nd clutch with the snap ring (I).
4. Install the idler gear (J) in the direction shown, the thrust needle bearing (K), the 1st gear collar (L), the needle bearing (M), the 1st gear assembly (N), the thrust needle bearing (O), and the 52 mm washer (P) in the direction shown on the secondary shaft.
5. Wrap the shaft splines with tape, and install new O-rings (Q) in the 1st/1st-hold clutch O-ring grooves, then remove the tape.
NOTE: To prevent damaging the O-rings, be sure to install the O-rings after installing the 1st gear collar and the 52 mm washer.
6. Install the 1st/1st-hold clutch (R).
7. Install the ball bearing (S) over the 1st/1st-hold clutch guide using the driver, 40 mm, the attachment, 30 mm, and a press.
8. Install a new splined washer (A) with the marked side (B) up over the ball bearing using the driver, 40 mm, the attachment, 30 mm, and a press.
9. Install a new locknut (A).
10. Place a V-block (A) on the back of a vise (B), and put the secondary shaft (C) on the V-block and the vise.
11. Attach the wrench, 40 x 42 mm onto the 1st clutch guide, and secure the wrench, 40 x 42 mm with the vise to hold the secondary shaft. Tighten the locknut to 178 N-m (18.2 kgf-m, 132 lbf-ft) using the torque wrench (D).
NOTE:
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ The locknut has left-hand threads.
12. Stake the locknut to a depth (A) of 0.7 - 1.3 mm (0.03 - 0.05 in.) using a 3.5 mm punch (B).
Secondary Shaft Installation Height Inspection/Adjustment
1. Install the thrust needle bearing (A) in the torque converter housing (B) in the direction shown, and install the secondary shaft assembly (C).
2. Install a new gasket (A) on the torque converter housing.
Secondary Shaft Cutaway View
3. Measure the installed height (B) of the secondary shaft between the surface (C) of the gasket and the top of the ball bearing outer race (D), then note the measurement.
4. Remove the 65 mm thrust shim (A) from the transmission housing, and measure its thickness.
5. Calculate the thickness of the 65 mm thrust shim using the formula.
Formula:
65 mm Thrust Shim Thickness
= Secondary Shaft Installation Height Standard
- Measurement
Secondary Shaft Installation Height
Standard:
222.54 - 222.63 mm (8.761 - 8.765 in.)
6. Select the 65 mm thrust shim from the following table.
7. Install the thrust shim in the transmission housing.