Manual Valve Operating Mechanism
Manual Valve Operating Mechanism1. Place the vehicle on a suitable hoist or over a pit, open the hood and disconnect the battery leads.
2. From underneath the vehicle, using a suitable container drain the transmission and discard the transmission pan seal.
3. Remove the oil filler level tube.
4. Remove the six retaining plates and bolts.
5. Remove the pan and discard the gasket.
6. Remove the oil screen, undoing the three bolts using a TX27 Torx bit.
7. Remove the valve body, undoing the thirteen remaining bolts using a TX27 Torx bit.
8. Locate the selector cam and remove the nipple holding the kick-down cable from its seat.
9. Remove the nut and gear change lever.
10. Using a suitable punch drift out the roll pin from the selector shaft and discard it.
11. Using a suitable tool remove the selector shaft from the box, noting the position of the detent plate.
12. Remove the connecting rod complete with detent plate, accelerator cam, spring and using a suitable tool remove the oil seal and discard.
13. Check all parts for wear or damage and replace as necessary.
14. Using selector shaft oil seal replacer LST 114, fit the oil seal. For ease of fitment use a light grease or Petroleum Jelly.
15. Fit connecting rod to detent plate and locate in the box by pushing the selector shaft through from outside of the casing.
NOTE: The detent plate should go back into the box in the same position as noted earlier.
16. Fit the accelerator cam with the spring.
17. Fit the assembly into the box and secure it by pushing the selector shaft through.
18. Align the hole in the selector shaft with the hole in the detent plate and secure with a new roll pin, using a suitable punch.
19. Fit kickdown cable nipple into the cam seat ensuring that the cam has been turned once before fitment. This will spring load the cam.
20. Fit the valve body ensuring the selector shaft locates into the gear shift fork and fit the thirteen bolts loosely by hand.
21. Place the selector linkage setting gauge LST109 in position and gently press the valve body against the tool and tighten all thirteen bolts using TX27 Torx bit to 8 Nm (6 ft lbs).
22. Remove the setting gauge and fit oil screen using TX27 Torx bit to 8 Nm (6 ft lbs).
23. Refit the oil pan with a new gasket.
24. Refit the six retaining plates and screws (two straight and four corner plates) to 8 Nm (6 ft lbs).
25. Reconnect the oil filler/level tube, pan plug with new seal to 60-75 Nm (45-55 ft lbs).
26. Connect the battery leads.
27. Fill the transmission with the correct oil.
28. Ensuring the vehicle is on level ground with the parking brake applied, check oil level while engine is running at idle with neutral selected, after selecting each gear.