2. Transmission/Flywheel Housing Disassemble & Service

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 flywheel housing (19 bolts).
2. Remove the differential assembly.
3. Remove the snap ring and thrust shim on the ATF pump drive sprocket, then remove the bolts securing the ATF pump drive sprocket.
4. Remove the ATF pump drive chain, then remove the ATF drive sprocket, sprocket hub, thrust washers and thrust needle bearing from the input shaft.
5. Remove the park pawl shaft, pawl shaft spring and park pawl.
6. Remove the snap ring securing the start clutch, and remove the cotter retainer and the cotters.





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





8. Remove the start clutch (A) and the secondary drive gear assembly (B) with the special tool.
9. Remove the secondary gear shaft.
10. Remove the secondary drive gear from the start clutch.





11. Remove the sealing ring (A) from the secondary drive gear (B), and clean it; the ring will be reinstalled on the new secondary drive gear when assembling the transmission.

ATF Pump Replacement
1. Remove the ATF pump drive sprocket mounting bolts, then remove the ATF pump drive chain.





2. Expand the snap ring under the ATF pump driven sprocket, and remove the ATF pump driven sprocket from the ATF pump.





3. Remove the ATF pump from the transmission housing.
4. Install the 22 x 10 mm ATF pipe (A) and the 18 x 10 mm ATF pipe (B) in the transmission housing, then install the new O-rings (C) over the ATF pipes.
5. Install the new ATF pump body (D) with the dowel pins (E). Do not pinch the O-rings.
6. Install the snap ring (F) in the snap ring groove.
7. Install the ATF pump driven sprocket.
8. Install the ATF pump drive chain and ATF pump 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 in the direction shown.
3. Expand the snap ring with the snap ring pliers, 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.

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 new oil seal in the flywheel housing with the special tools in the specification shown.

Secondary Gear Shaft Thrust Clearance Inspection

NOTE: If the transmission housing or flywheel housing was replaced, secondary gear shaft thrust clearance must be inspected.








1. Install the secondary gear shaft in the transmission housing.
2. Measure the distance (A) between the transmission housing surface and the top of the bearing, then note the measurement (Measurement A).








3. Measure the distance (B) between the flywheel housing surface and bearing mounting surface in the housing, then note the measurement (Measurement B).
4. Calculate the secondary gear shaft clearance by subtracting Measurement B from Measurement A.
Standard: 0.5 - 0.65 mm (0.02 - 0.03 inch)

NOTE: The standard of the clearance includes the thickness of the flywheel housing gasket (0.5 mm, 0.02 inch)

5. If the clearance is out of standard, adjust it with the 25 x 35 mm thrust shim.

Secondary Gear Shaft Bearing Replacement

Special Tools Required
^ Driver 40 mm I.D.07746-0030100
^ Attachment, 25 mm I.D. 07746-0030200





1. Remove the bearing (A) from the secondary gear shaft (B) with a universal two-jaw (or three-jaw) puller (C). Place a shaft protector (D) between the secondary gear shaft and a puller to prevent damaging the shaft.





2. Install the new bearing (A) on the secondary gear shaft (B) of the transmission housing side with the special tools and a press.
3. Select the 25 x 35 mm thrust shim.





4. Install the selected thrust shim, then install the new bearing (A) on the secondary gear shaft (B) of the flywheel housing side using the special tools and-a press.

25 x 35 mm Thrust Shim Selection

NOTE: If the secondary gear shaft bearings or secondary gear shaft is replaced, select the 25 x 35 mm thrust shim to adjust the secondary gear shaft thrust clearance.

1. Remove the bearing on flywheel housing side of the secondary gear shaft.
2. Install the secondary gear shaft in the transmission housing.








3. Measure the distance (A) between the transmission housing surface and the 25 x 35 mm thrust shim mounting surface on the secondary gear shaft, then note the measurement (Measurement A).








4. Measure the distance (B) between the flywheel housing surface and bearing mounting surface in the housing, then note the measurement (Measurement B).





5. Calculate the thickness of the 25 x 35 mm thrust shim using the formula.





6. Select the 25 x 35 mm thrust shim using the table.
7. Remove the secondary gear shaft from the transmission housing.
8. Install the selected 25 x 35 mm thrust shim in the secondary gear shaft, then install the bearing.

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 By.
3. Install the secondary gear shaft (D) in the transmission housing.
4. Wrap the driven pulley shaft splines with tape to prevent O-rings damage, install the new O-rings (E) in the shaft O-ring grooves, and remove the tape.
5. Install the secondary drive gear assembly (F) in the new start clutch (G), then install them on the driven pulley shaft (H).





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 coffers in 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). Take measurements in at least three places, and use the average as the actual clearance.
10. If the clearance is out of standard, remove the cutters, and measure their thickness.





11. Select and install the new 25.5 mm coffers as a set, 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 the 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). Take measurements in at least three places, and use the average as the actual clearance.
18. If the clearance is out of standard, remove the 22 x 28 mm thrust shim, and measure its thickness.





19. Select and install a new 22 x 28 mm thrust shim, then recheck.
20. After replacing the 22 x 28 mm thrust shim, make sure the clearance is within the tolerance and the snap ring outside diameter is correct.





21. Install the ATF pump drive sprocket (A) on the sprocket hub (B), and put the ATF pump drive chain (C) on the ATF pump drive sprocket and ATF pump driven sprocket (D), then install and tighten the three bolts.





22. Install the differential assembly (A).
23. Install the ATF feed pipe (B) with a new O-ring (C) in the transmission housing (D).
24. Install the three dowel pins (E) and new flywheel housing gasket (F) on the transmission housing.
25. Install a new O-ring (G) over the ATF feed pipe.
26. Install the flywheel housing (H) and tighten the mounting bolts with the harness clamp bracket (1).