Part 1
Mainshaft Disassembly, Inspection, and Reassembly1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
Mainshaft:
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent the O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and the 41 x 68 mm thrust washer in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission.
8. Check the clearance of 5th gear.
Mainshaft 5th Gear Axial Clearance Inspection
'04-06 Models
1. Remove the mainshaft transmission housing bearing.
2. Install the 41 x 68 mm thrust washer (A), the 4th/5th clutch (B), the 4th gear collar (C), and the transmission housing bearing (D) on the mainshaft (E). Do not install the O-rings during inspection.
3. Install the idler gear (F) on the mainshaft with a press, then install the conical spring washer (G) and the locknut (H).
4. Tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
5. Measure the clearance between the mainshaft flange (A) and the 41 x 68 mm thrust washer (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance.
6. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness (A).
7. Select and install a new thrust washer, then recheck.
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.
10. Reinstall the bearing in the transmission housing.
'07-08 Models
1. Remove the mainshaft transmission housing bearing.
2. Install the thrust needle bearing (A), 5th gear (B), the needle bearing (C), the thrust needle bearing (D), the 41 x 68 mm thrust washer (E), the 4th/5th clutch (F), the 4th gear collar (G), and the transmission housing bearing (H) on the mainshaft (I). Do not install the O-rings during inspection.
3. Install the idler gear (J) on the mainshaft with a press, then install the conical spring washer (K) and the locknut (L).
4. Tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
5. Set the dial indicator (A) on 5th gear (B).
6. Lift 5th gear (A) up while holding the mainshaft, and use the dial indicator (B) to read the 5th gear axial clearance.
7. Measure the 5th gear axial clearance in at least three places while moving 5th gear. Use the average as the actual clearance.
Standard: 0.04-0.10 mm (0.002-0.004 in.)
8. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness (A).
9. Select and install a new thrust washer, then recheck.
10. After replacing the thrust washer, make sure the clearance is within the standard.
11. Disassemble the installed parts from the mainshaft.
12. Reinstall the bearing in the transmission housing.
Countershaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
Countershaft:
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, reverse selector, 35 x 47 x 7.8 mm collar, and all gears in the direction shown.
6. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The countershaft locknut has left-hand threads.
7. Some reverse selector hubs and 3rd gear are press-fitted to the countershaft; special tools are needed to remove them and to install them.
Countershaft Reverse Selector Hub and 3rd Gear Removal
1. Install the bearing separator on 4th gear (A). Set a press on the countershaft (B) with a spacer (C) between the press and the countershaft. Support the bottom of the countershaft with one hand, then press the countershaft out of the press-fitted reverse selector hub. The countershaft will drop down after pressing it out of the press-fitted reverse selector hub.
NOTE: Some reverse selector hubs are not press-fitted, and can be removed without using the bearing separator and a press.
2. Remove the needle bearing, the set ring, the 35 x 47 x 7.8 mm collar, and the cotters.
3. Set the press on the countershaft (A) with a spacer (B) between the press and countershaft. Support the bottom of the countershaft with one hand, then press the countershaft out of 3rd gear. The countershaft will drop down after pressing it out of 3rd gear.
4. Remove the 37 x 41 x 54.3 mm collar, 5th gear, 1st gear, and 2nd gear.
Countershaft 3rd Gear and Reverse Selector Hub Installation
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Apply ATF to the parts.
2. Install 2nd gear, 1st gear, 5th gear, and the 37 x 41 x 54.3 mm collar on the countershaft.
3. Slide 3rd gear (A) over the countershaft, and press it in place using the 40 mm driver and a press.
4. Install the cotters, the 35 x 47 x 7.8 mm collar, the set ring, the needle bearing, and 4th gear.
5. Slide the reverse selector hub (A) over the countershaft, then press it in place using the 40 mm driver and a press.
NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the 40 mm driver and a press.
Secondary Shaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
Secondary Shaft:
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent the O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and the idler gear in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the clearance of 2nd gear and 1st gear.
Secondary Shaft Ball Bearing, Idler Gear Removal and Installation
Special Tools Required
Attachment, 42 mm I.D. 07QAD-P0A0100
Removal
Place a shaft protector (A) on the secondary shaft (B), and set the puller (C) under the idler gear (D), then remove the idler gear and the ball bearing (E).
Installation
Install the idler gear (A) on the secondary shaft (B), and install the ball bearing (C) over the idler gear using the 42 mm attachment and a press.
Secondary Shaft 2nd Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), the needle bearing (B), 2nd gear (C), the thrust needle bearing (D), the 37 x 58 mm thrust washer (E), and the 2nd clutch (F) on the secondary shaft (G), then secure them with the snap ring (H). Do not install the O-rings during inspection.
2. Measure the clearance between the snap ring (A) and the 2nd clutch guide (B) using a feeler gauge (C), in at least three places. Use the average as the actual clearance.
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer, and measure its thickness.
4. Select and install a new thrust washer, then recheck.
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the shaft and the gears.
Secondary Shaft 1st Gear Axial Clearance Inspection
Special Tools Required
Attachment, 42 mm I.D. 07QAD-P0A0100
1. Install the thrust needle bearing (A), the needle bearing (B), 1st gear (C), the thrust needle bearing (D), the 40 x 51.5 mm thrust washer (E), the 1st/3rd clutch (F), and the 3rd gear collar (G) on the secondary shaft (H). Do not install the O-rings during inspection.
2. Install the idler gear (I), then install the ball bearing (J) on the idler gear using the 42 mm attachment and a press.
3. Install the conical spring washer (K) and the locknut (L), then tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
4. Turn the secondary shaft assembly upside down, and set the dial indicator (A) on 1st gear (B).
5. Lift 1st gear (A) up while holding the secondary shaft, and use the dial indicator (B) to read the 1st gear axial clearance.
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 40 x 51.5 mm thrust washer, and measure its thickness.
8. Select and install a new thrust washer, then recheck.
THRUST WASHER_ AA x 51.5 mm
9. After replacing the thrust washer, make sure the clearance is within standard.
10. Disassemble the shaft and the gears.
Idler Gear Shaft Removal and Installation
1. Remove the snap ring (A), the cotter retainer (B), and the cotters (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap ring and the cotter retainer for wear and damage. Replace them if they are worn, distorted, or damaged.
4. Install the idler gear and the shaft in the reverse order of removal.
Idler Gear/Idler Gear Shaft Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 32 x 35 mm 07746-0010100
1. Remove the snap ring from the idler gear/idler shaft assembly.
2. Remove the idler gear shaft (A) from the idler gear (B) using the driver and the 32 x 35 mm attachment and a press.
3. Replace the idler gear or the idler gear shaft, and attach the idler gear shaft to the idler gear.
4. Install the idler gear shaft (A) in the idler gear (B) using the driver and the 32 x 35 mm attachment and a press.
5. Install the snap ring.
Clutch Disassembly
Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
1. Remove the snap ring using a screwdriver.
2. 1st clutch: Remove the clutch end-plate (A), the clutch discs (B) (5), the clutch flat-plates (C) (5), and the waved spring (D) from the 1st clutch drum (E).
3. '04-05 models 2nd clutch: Remove the clutch end-plate (A), the clutch discs (B) (5), the clutch wave-plates (C) (3), the 2.0 mm-thick flat-plate (D), the 4.0 mm-thick plate (E), and the waved spring (F) from the 2nd clutch drum (G).
4. Make a reference mark on the 2.0 mm-thick flat-plate.
5. '06-08 models 2nd clutch: Remove the clutch end-plate (A), the clutch discs (B) (6), the clutch wave-plates (C) (5), the clutch flat-plate (D) (1), and the waved spring (E) from the 2nd clutch drum (F).
6. Make reference marks on the clutch wave-plates.
7. '04-05 models 3rd clutch: Remove the clutch end-plate (A), the clutch discs (B) (5), the clutch flat-plates (C) (5), and the waved spring (D) from the 3rd clutch drum (E).
8. '06-08 models 3rd clutch: Remove the clutch end-plate (A), the clutch discs (B) (6), the clutch flat-plates (C) (6), and the waved spring (D) from the 3rd clutch drum (E).
9. '04-05 models 4th clutch: Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 4th clutch drum (E).
10. '06-08 models 4th clutch: Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 4th clutch drum (E).
11. '04-05 models 5th clutch: Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 5th clutch drum (E).
12. '06-08 models 5th clutch: Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch wave-plates (C) (4), and the waved spring (D) from the 5th clutch drum (E).
13. Install the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
14. Set the clutch spring compressor attachment (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches so the clutch spring compressor works on the clutch return spring (C).
15. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.
16. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.
17. Compress the return spring until the snap ring can be removed.
18. Remove the snap ring using the snap ring pliers.
19. Remove the clutch spring compressor attachment and the clutch spring compressor bolt assembly.
20. Remove the snap ring (A), the spring retainer (B), and the return spring (C).
21. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other passage while applying air pressure.
22. 1st, 2nd, and 3rd clutches: Remove the clutch piston (A), remove the O-ring (B) from the piston, and remove the O-ring (C) from the clutch drum (D).
23. 4th and 5th clutches: Remove the clutch piston (A), and remove the outer O-ring (B) and the inner O-ring (C) from the piston.
