2. Automatic Transmission Reassembly

Automatic Transmission Reassembly

Special Tools Required

- Mainshaft Holder Set 07PAB-0010001

Refer to the Exploded View in the Transmission Disassembly as needed during the following procedure.

1. Make sure that the ATF magnet (A) is cleaned and installed in the torque converter housing. Clean and install the ATF magnet, if necessary.









2. Install the main separator plate (B) and the two dowel pins (C) on the torque converter housing.

3. Install the ATF pump drive gear (D), the ATF pump driven gear (E), and the ATF pump driven gear shaft (F). Install the ATF pump driven gear with its grooved and chamfered side facing down.

4. Install the main valve body (G) (eight bolts).

5. Install the 4th/reverse air check valve (H).

6. Make sure the ATF pump drive gear (A) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (B) moves smoothly in the axial and normal operating direction.





7. If the ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torques, then recheck. 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.

8. Install the two check balls (A) in the main valve body.





9. Install the regulator separator plate (B) and the two dowel pins (C) on the main valve body, and install the regulator valve body (D) (eight bolts).

10. Install the manual separator plate (E) and the two dowel pins (F) on the main valve body, and install the manual valve body (G) (seven bolts).

11. Install the two dowel pins (A) on the main valve body.





12. Install the stator shaft (B) with new O-rings (three) (C), and install the stator shaft support (D) (four bolts).

13. Install the 3rd air check valve (E) and the 6th air check valve (F).

14. Install the stator shaft stop (G) in the torque converter housing.

15. Install the cooler retainer cap (A).






16. Install the 2nd air check valve (A), the 5th air check valve (B), and the oil catch plate (C).





17. Install the transfer output shaft (D) in the torque converter housing, and install the thrust shim (E) on the top of the transfer output shaft.

18. Install the differential assembly (F) in the torque converter housing.

19. Install the selector control shaft (G).

20. Align the control lever pin (A) with the manual valve guide (B).






21. Hook the detent arm spring (A) to the detent arm (B) and the selector control shaft (C), then install the detent arm and the detent arm shaft (D) into the torque converter housing.






22. Assemble each shaft:

- Mainshaft A/T Main Shaft Reassembly
- Countershaft A/T Countershaft Reassembly
- Secondary shaft A/T Secondary Shaft Reassembly
- Third shaft A/T Third Shaft Reassembly
- Idler gear shaft A/T Idler Gear Shaft Reassembly

23. Install the parking holder (A).





24. Install the third shaft subassembly (B) into the main valve body.

25. Install the thrust needle bearing (A) on the secondary shaft bearing in the torque converter housing in the direction shown.





26. Join the mainshaft subassembly (B), the countershaft subassembly (C), the secondary shaft subassembly (D), and the idler gear shaft (E) together, and install them in the torque converter housing. Install the 27.5 x 41 x 2.5 mm thrust needle bearing (F) and the 41.5 mm washer (G) on the top of the idler gear shaft.

27. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole of the reverse shift fork (B).






28. Install the baffle plate (C), the reverse shift fork, the reverse selector (D), and the reverse gear (E) together.

29. Secure the reverse shift fork (A) to the shift fork shaft with the lock bolt (B) and a new lock washer (C), then bend the lock tab of the lock washer against the bolt head.






30. Install the ATF lubrication pipe (A) and the 10 x 70 mm ATF feed pipe (B) into the regulator valve body (C).





31. Install the ATF strainer (D) with a new O-ring.

32. Install new O-rings (A) (four) on the joint pipes (B) (two), and install the joint pipes into the manual valve body (C) and the torque converter housing (D).






33. Install the two dowel pins (A) and a new gasket (B) on the torque converter housing (C).





34. Place the transmission housing (D) on the torque converter housing.

35. Wrap a screwdriver tip with tape to prevent damaging the reverse idler gear teeth. Engage the reverse idler gear with the third shaft reverse gear and mainshaft 3rd gear by rotating the reverse idler gear using the screwdriver.






36. While expanding the snap ring of the countershaft bearing using snap ring pliers, install the transmission housing onto the bearing part-way. Then release the snap ring pliers, and push down the transmission housing until it bottoms and snap ring snaps into place in the countershaft bearing snap ring groove.






37. Install the transmission housing mounting bolts along with transmission hanger C, and tighten the bolts in at least two steps in a criss-cross pattern to the specified torques.






38. Install the mainshaft holder onto the mainshaft.






39. Install the control lever (A) over the selector control shaft (B). Secure the control lever with a new lock washer (C) and the bolt, then bend the lock tab of the lock washer against the bolt head.






40. Shift the transmission into P by rotating the control lever. Do not use the control shaft to adjust the shift position. If the selector control shaft tips are squeezed together, it will cause a faulty signal or position due to play between the control shaft and the transmission range switch.






41. Install the old splined washers (A) with the marked side (B) up over the mainshaft (C) and the third shaft (D), and apply ATF to surfaces of the old splined washers and the old locknuts (E).





42. Install the old locknuts, and tighten them to seat the splined washers to the specified torques, then remove the old locknuts and the old splined washers.

NOTE: The third shaft locknut has left-hand threads.

43. Install new locknuts and new splined washers, and tighten them to the specified torques, then stake the locknuts to a depth (A) of 0.7-1.3 mm (0.03-0.05 in) using a 3.5 mm punch (B).

NOTE: Do not rotate the locknuts in the reverse direction after the locknuts are seated to the splined washers.





44. Remove the mainshaft holder from the mainshaft.

45. Install transmission hanger A.





46. Install a new O-ring (B) on the mainshaft end cover (C), and install the mainshaft end cover. Install a new O-ring (D) on the third shaft end cover (E), and install the third shaft end cover with the ATF filter bracket (F).

47. Install new O-rings (G) on the end covers (H), and install the end covers.

48. Apply ATF to new O-rings (A), and install the O-rings over the ATF pipes (B). Then install the ATF pipes with the filter ends (C) facing the secondary valve body (D) into the transmission.

NOTE: There are 11 ATF pipes. Do not drop the ATF pipes into the transmission. If an ATF pipe is dropped into the transmission, the transmission will need to be disassembled.





49. Install a new gasket (E) on the transmission housing.

50. Install the secondary valve body while aligning the ATF pipes with the pipe holes on the secondary valve body, and secure the secondary valve body with the bolts.

51. Install new O-rings (A) on shift solenoid valve C (B), and install shift solenoid valve C.





52. Install transmission fluid pressure switch C (4th clutch) (C) with a new sealing washer (D). Tighten the switch by gripping the metal part, not the plastic part.

53. Install transmission fluid pressure switch A (2nd clutch) (A) with a new sealing washer (B). Tighten the switch by gripping the metal part, not the plastic part.





54. Install transmission fluid pressure switch D (5th clutch) (C) with a new sealing washer (D). Tighten the switch by gripping the metal part, not the plastic part.

55. Install transmission hanger B (E).

56. Install the ATF outlet line (A), and secure it with the banjo bolt (B) and new sealing washers (C), then secure the ATF outlet line with the bracket bolt.





57. Install the ATF inlet line/ATF hose/ATF filter (D), and secure it with the banjo bolt (E) and new sealing washers (F), then secure the ATF inlet line with the bracket bolt.

58. Put the ATF filter (G) on the ATF filter bracket (H), and secure it with the ATF filter holder (I) and the bolt.

59. Install a new O-ring (A) on the ATF temperature sensor (B), and install the ATF temperature sensor.






60. Install a new O-ring (A) on the input shaft (mainshaft) speed sensor (B), and install the input shaft (mainshaft) speed sensor.





61. Install a new O-ring (C) on the output shaft (countershaft) speed sensor (D), and install the output shaft (countershaft) speed sensor.

62. Shift the transmission into N by rotating the control lever. Do not use the selector control shaft to adjust the shift position. If the selector control shaft tips are squeezed together, it will cause a faulty signal or position due to play between the selector control shaft and the transmission range switch.






63. Align the cutouts (A) on the rotary-frame with the N positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 in) feeler gauge blade (D) in the cutouts to hold the switch in the N position.

NOTE: Be sure to use a 2.0 mm (0.08 in) blade or equivalent to hold the switch in the N position.






64. Install the transmission range switch (A) gently on the selector control shaft while holding it in the N position with the 2.0 mm (0.08 in) blade (B).





65. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge.

66. Install the dipstick guide tubes (A) with new O-rings (B).





67. Install the ATF dipstick in the dipstick guide tube.