2. Transmission Housing/Flywheel Housing

Flywheel Housing and Start Clutch Removal

Special Tools Required
Start clutch remover 07TAE-P4VA120

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Remove the ATF passage line holder.
2. Remove the flywheel housing (20 bolts).
3. Remove the ATF passage line (one bolt).
4. Remove the ATF pump drive sprocket (three bolts), and remove the ATF pump drive chain.





5. Move the pilot flange (A) toward its cutout (B) to clear the pilot pipe (C) under the pilot flange, and remove the pilot flange.
6. Remove the snap ring securing the ATF pump drive sprocket hub, and remove the 22 x 28 mm thrust shim, ATF pump drive sprocket hub, thrust washers, and thrust needle bearing.
7. Remove the differential assembly.
8. Remove the park pawl shaft, park pawl spring, and park pawl.
9. Remove the snap ring securing the start clutch, and remove the cotter retainer and the cotters.





10. Set the special tool on the start clutch (A), and attach the jaws (B) of the special tool to the park gear (C) securely. Do not place the jaws of the special tool on the start clutch guide. If the jaws contacts the start clutch guide, the clutch guide may be damaged. Be sure not to allow dust and other foreign particles to enter into the driven pulley shaft.





11. Remove the start clutch (A) and the secondary drive gear assembly with the special tool.





12. Remove the sealing ring (A) from the secondary drive gear (B), and clean it; it is reinstalled on the new secondary drive gear when assembling the transmission.
13. Remove the secondary gear shaft.

ATF Pump Replacement





1. Remove the ATF pump drive sprocket bolts (A), and remove the ATF pump drive sprocket (B) and ATF pump drive chain (C).
2. Move the pilot flange (D) toward its cutout (E) to clear the pilot pipe (F) under the pilot flange, and remove the pilot flange.





3. Expand the snap ring (A) under the ATF pump driven sprocket (B) with the snap ring pliers, then remove the ATF pump driven sprocket.
4. Remove the old ATF pump body from the transmission housing.





5. Install the 22 x 10 mm ATF pipe (A) and 18 x 10 mm pipe (B) in the transmission housing, then install the new O-rings (C) over the ATF pipes.
6. Install the new ATF pump body (D). Do not pinch the O-rings.
7. Install the snap ring (F) in the snap ring groove.
8. Install the ATF pump driven sprocket.
9. Install the pilot flange using its cutout to clear the pilot pipe.
10. Install the ATF drive chain and ATF drive sprocket.

Driven Pulley Shaft Bearing Removal and Installation

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 72 x 75 mm 07746-0010600

NOTE: Coat all parts with ATF before assembly.

1. To remove the driven pulley shaft bearing from the transmission housing, expand the snap ring with the snap ring pliers, then push the bearing out.

NOTE: Do not remove the snap ring unless it's necessary to clean the groove in the housing.





2. Install the bearing (A) in the direction shown.
3. Expand the snap ring with the special tool, and install 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 bearing verify that the snap ring (A) is seated in the bearing and housing grooves, and that the ring end gap (B) is correct.

Secondary Gear Shaft Transmission Housing Bearing Replacement

Special Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 72 x 75 mm 07746-0010600





1. Remove the secondary gear shaft bearing (A) from the transmission housing (B) with the special tool.





2. Install the new secondary gear shaft bearing until it bottoms in the transmission housing with the special tools.

Secondary Gear Shaft Flywheel Housing Bearing Replacement

Special Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 62 x 68 mm 07746-0010500





1. Remove the secondary gear shaft bearing (A) from the flywheel housing (B) with the special tool.





2. Install the new secondary gear shaft bearing until fit bottoms in the flywheel housing with the special tools.

Flywheel Housing Input Shaft Oil Seal Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 32 x 35 mm 07746-0010100





1. Remove the input shaft oil seal (A) from the flywheel housing (B).





2. Install the oil seal (A) in the flywheel housing (B) with the special tools.

Control Shaft Assembly Removal and Installation





1. Remove the bolt (A) and lock washer (B).
2. Remove the control lever (c) from the control shaft (D).
3. Remove the control shaft assembly from the transmission housing (E).
4. Install the control shaft assembly in the transmission housing.
5. Install the control lever to the control shaft.
6. Install and tighten the bolt with the new lock washer.

Transmission Housing/Flywheel Housing
Start Clutch and Flywheel Housing Installation

Special Tools Required
Start clutch installer 07TAE-P4VA130





1. Install the sealing ring (A) on the new secondary drive gear (B).





2. Install the park pawl (A), pawl spring (B) and pawl shaft (C) in the transmission housing, then move the control lever to any position other than P.
3. Install the secondary gear shaft (D) with selected 25 x 35 thrust shim (E).
4. Wrap the driven pulley shaft splines with tape to prevent O-ring damage, install the new O-rings (F) in the shaft O-ring grooves, and remove the tape.
5. Install the secondary drive gear assembly (G) in the start clutch (H), then install them on the driven pulley shaft (I).





6. Pull the handle of the special tool up, then install the tip of it into the driven pulley shaft feed pipe hole, and set the special tool on the start clutch. Do not allow dirt or other foreign particles to enter into the transmission,





7. Push the handle (A) of the special tool, then tighten the nut to seat the secondary drive gear assembly on the drive pulley shaft.
8. Pull the handle of the special tool up, and remove the special tool.





9. Install the 25.5 mm cotters to the cotter groove on the driven pulley shaft, then measure the clearance between the cotters (A) and the start clutch guide (B) with a feeler gauge (C).

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

STANDARD: 0 - 0.13 mm (0 - 0.005 inch)
10. If the clearance is out of standard, remove the cotters, and measure their thickness.





11. Select and install the new 25.5 mm cotters, then recheck.
12. After replacing the cotters, make sure that the clearance is within the tolerance.
13. Install the cotter retainer and snap ring.





14. Verify that the snap ring outside diameter (A) is 33.9 mm (1.33 inch) or less.





15. Install the thrust washer (A), thrust needle bearing (B), thrust washer (C), ATF pump drive sprocket hub (D), 22 x 28 mm thrust shim (E), and snap ring (F) on the input shaft (G).





16. Verify that snap ring outside diameter (A) is 26.3 mm (1.04 inch) or less.





17. Measure the clearance between the 22 x 28 mm thrust shim (A) and snap ring (B) with a feeler gauge (C).

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

STANDARD: 0.37 - 0.65 mm (0.015 - 0.026 inch)
18. If the clearance is out of standard, remove the 22 x 28 mm thrust shim, and measure its thickness.
19. Select and install the new 22 x 28 mm thrust shim, then recheck.





THRUST SHIM, 22 x 28 mm
20. After replacing the 22 x 28 mm thrust shim, make sure that the clearance is with in the tolerance and the snap ring outside diameter is correct.





21. install the pilot flange (A) using its cutout (B) as shown to clear the pilot pipes (C).





22. Install the ATF pump drive sprocket (A), and put the ATF pump drive chain (B) on the ATF pump drive and driven sprockets, then install and tighten the three bolts.





23. Install the differential assembly (A).
24. Install the ATF passage line assembly (B) with the new O-rings (C).
25. Install the three dowel pins (D) and new flywheel gasket (E) on the transmission housing.
26. Install the flywheel housing (F) (20 bolts).
27. Install the ATF passage line holder assembly (G) with the new O-ring (H) (two bolts).