Part 4

OIL SEALS
Replacement
1. Remove the differential assembly.





2. Remove the oil seal from the transmission housing.





3. Remove the oil seal from the torque converter housing.





4. Install the oil seal in the transmission housing with the special tools.





5. Install the oil seal in the torque converter housing with the special tools.

TORQUE CONVERTER HOUSING BEARINGS
Mainshaft Bearing / Oil Seals Replacement





1. Remove the mainshaft bearing and oil seal using the special tools as shown.





2. Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown.





3. Install the new oil seal flush with the housing using the special tools as shown.

Countershaft Bearing Replacement





1. Remove the countershaft bearing using the special tool as shown.
2. Install the ATF guide plate.





3. Install the new bearing into the housing using the special tools as shown.

Secondary Shaft Bearing Replacement





1. Remove the secondary shaft bearing using the special tool as shown.
2. Install the ATF guide plate.





3. Install the new bearing into the housing using the special tools as shown.

TRANSMISSION HOUSING BEARINGS
Removal / Installation

NOTE: Coat all parts with ATF before assembly





1. To remove the mainshaft, countershaft, and secondary shaft bearings from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out using the following special tools and a press.

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

Special Tools Required: (Use with Driver (07749 - 0010000))
Mainshaft:
- Driver Attachment, 58 mm (07JAD - PH80101)
Countershaft and Secondary Shaft:
- Driver Attachment, 72 x 75 mm (07746 - 0010600)

2. Install the bearings in the direction shown.
3. Expand each snap ring with the snap ring pliers, and insert the bearing part-way into the housing using the special tools and a press.





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 bearings verify the following:
- The snap rings are seated in the bearing and housing grooves.
- The ring end gaps are correct.

PARK BRAKE STOP
Inspection / Adjustment
1. Set the parking brake lever in the [P] position.





2. Measure the distance between the parking brake pawl shaft and the parking brake lever roller pin as shown.





3. If the measurement is out of tolerance, select and install the appropriate parking brake stop from the table below.
4. After replacing the parking brake stop, make sure the distance is within tolerance.

TRANSMISSION
Reassembly








NOTE:
^ Coat all parts with ATF.
^ Replace the following parts:
- O-rings
- Lock washers
- Gaskets
- Locknuts and conical spring washers
- Sealing Washers

Torque:
- 6 x 1.0 mm: 12 Nm (8.7 ft. lbs.)
- 8 x 1.25 mm: 18 Nm (13 ft. lbs.)





1. Install the main separator plate and three dowel pins on the torque converter housing. Then install the ATF pump gears and ATF pump driven gear shaft.

NOTE: Install the ATF pump driven gear with its grooved and chamfered side facing down.





2. Install the torque converter check valve and spring, then install the main valve body (one 6 mm bolt and three 8 mm bolts). Make sure the ATF pump drive gear rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft moves smoothly in the axial and normal operating direction.
3. 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 torque, then recheck.

CAUTION: 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.

4. Install the cooler check valve and spring on the main valve body, then install the two dowel pins and the regulator separator plate.
5. Install the stator shaft and stator shaft stop.
6. Install the regulator valve body (eight bolts).
7. Install the two dowel pins and the servo separator plate on the main valve body.
8. Install the control shaft in the torque converter housing, along with the manual valve.





9. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm.
10. Install the servo body (nine bolts).
11. Install the accumulator cover (two bolts).
12. Install the ATF strainer (two bolts).
13. Install the servo detent base (two bolts).
14. Install the accumulator body (six bolts).
15. Install the two ATF feed pipes in the servo body, four pipes in the regulator valve body, and one pipe in the main valve body.
16. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing.
17. Install the countershaft 4th gear and reverse selector hub on the countershaft. If the reverse selector hub is a press-fitted type, refer to the installation.





18. Turn the shift fork shaft so the large chamfered hole is facing the fork bolt hole. Then install the shift fork and reverse selector together on the shift fork shaft and countershaft. Secure the shift fork to the shift fork shaft with the lock bolt and a new lock washer, then bend the lock washer against the bolt head.
19. Install the needle bearing, countershaft reverse gear, and countershaft 2nd gear on the countershaft.





20. Install the reverse idler gear in the transmission housing in the direction shown, then slip it the direction as shown.





21. Align the spring pin of the control shaft with the transmission housing groove by turning the control shaft.
22. Install three dowel pins and a new gasket on the torque converter housing.
23. Place the transmission housing on the torque converter housing.





24. Install the transmission housing mounting bolts along with the transmission hanger/connector bracket, transmission hangers, connector bracket, and transmission ground terminal bracket/connector bracket. Tighten the bolts in two or more steps in the sequence shown.





25. Install the ATF feed pipes with their filter side into the transmission housing, then install new O-rings, a new gasket, the harness clamp bracket, and the A/T clutch pressure control solenoid valve A/B assembly over the ATF feed pipes on the transmission housing.





26. Coat the reverse idler gear shaft, needle bearing, and new O-rings with lithium grease lightly. Assemble new O-rings and needle bearing on the reverse idler gear shaft, then install the reverse idler gear shaft in the reverse idler gear shaft holder. Align the D-shaped cut out of the shaft with the D-shaped area of the holder.





27. Engage the reverse idler gear with the countershaft reverse gear and mainshaft reverse gear, then install the reverse idler gear shaft/holder assembly on the transmission housing.





28. Install the parking brake lever on the control shaft, then install the lock bolt with a new lock washer.

NOTE: Do not bend the lock tab of the lock washer in this step, bend it after checking parking brake pawl engagement in step 47.

29. Coat the following parts with ATF:
- Splines of the countershaft, the parking gear and the old locknut.
- Threads of the countershaft and the old locknut.
- Old conical spring washer.





30. Install the parking gear using the old locknut and a collar. Hold the parking brake pawl to engage with the parking gear, then tighten the old locknut until the countershaft splines come out slight amount of the splines over the parking gear.





31. Remove the locknut and the collar, then install the bearing hub/bearing assembly and old conical spring washer. Tighten the old locknut to seat the parking gear to the specified torque, then loosen and remove the locknut and conical spring washer.

TORQUE: 226 Nm (166 ft. lbs.)

NOTE: Do not use an impact wrench. Always use a torque wrench to tighten the locknut.





32. Remove the bearing hub/bearing assembly using a puller as shown.





33. Install the thrust needle bearing, needle bearing, countershaft idler gear, thrust needle bearing, bearing hub/bearing assembly and the old conical spring washer. Then tighten the old locknut to seat the bearing hub/bearing assembly to the specified torque.

TORQUE: 167 Nm (123 ft. lbs.)

NOTE: Do not use an impact wrench. Always use a torque wrench to tighten the locknut.





34. Set the dial indicator to the countershaft idler gear as shown.





35. Measure the countershaft idler gear axial clearance while moving the countershaft idler gear.

STANDARD: 0.015 - 0.045 mm (0.0006 - 0.0018 inch)

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

36. If the clearance is out of standard, remove the bearing hub/bearing assembly using a puller.





37. Select and install the new bearing hub/bearing assembly, then recheck.
38. After replacing the bearing hub/bearing assembly, make sure that the clearance is within the standard.
39. Remove the old locknut and old conical spring washer from the countershaft.





40. Install the special tool onto the mainshaft as shown.
41. Coat the following parts with ATF:
- Splines of the mainshaft, secondary shaft, and those idler gears.
- Threads of the mainshaft, secondary shaft, and the new locknuts.
- New conical spring washers.





42. Install the new conical spring washers and the new locknuts on each shaft. Install the conical spring washer in the direction shown.
43. Tighten the locknuts to the specified torque using a torque wrench.

TORQUE: 167 Nm (123 ft. lbs.)

NOTE:
^ Do not use an impact wrench, Always use a torque wrench to tighten the locknut.
^ Mainshaft locknut has left-hand threads.





44. Stake each locknut into its shaft using a 3.5 mm punch as shown.
45. Set the parking brake lever in the [P] position, then verify that the parking brake pawl engages the parking gear.
46. If the parking brake pawl does not engage fully, check the distance between the parking brake pawl shaft and the parking brake lever roller pin as described.





47. Tighten the lock bolt, and bend the lock tab against the lock bolt head.





48. Install the right side cover with two dowel pins and new O-rings (14 bolts).

TORQUE: 12 Nm (8.7 ft. lbs.)





49. Set the control shaft in the [N] position by turning the control shaft.





50. Set the A/T gear position switch to W position.
51. Install the A/T gear position switch gently on the control shaft, then secure it with the bolts.

NOTE: Take care not to move the A/T gear position switch when tightening the bolts.





52. Install the A/T gear position switch cover, and secure the harness clamp on the right side cover with the bolts. Install the harness clamp on the clamp bracket.
53. Install the ATF cooler lines with new sealing washers.

TORQUE: 28 Nm (21 ft. lbs.)

54. Install the breather tube.
55. Install the ATF dipstick.