A/T Shaft Assembly And Housing Installation

A/T Shaft Assembly and Housing Installation

NOTE: The illustration shows the 4WD transmission; the 2WD does not have the transfer assembly.

1. Install the differential assembly in the torque converter housing.






2. Install the baffle plate (A) on the servo body. Install the new baffle plate if the old baffle plate (B) was installed.





3. Assemble the mainshaft, the countershaft, and the secondary shaft.

4. Join the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly (C) together, and install them in the torque converter housing. Do not bump the countershaft on the baffle plate (D).





5. Make sure the countershaft subassembly and the differential are clear of the baffle plate.

6. If the detent arm was removed, install the detent arm (A) with the arm collar (B) on the servo body (C), and install a new lock washer (D) by aligning its cutout (E) with the projection (F) of the servo body. Install and tighten the bolt, then bend the lock tab of the lock washer against the bolt head.






7. Install the selector control shaft (A) in the torque converter housing aligning the manual valve lever pin (B) on the selector control shaft with the guide of the manual valve (C). Pull the manual valve gently when aligning the manual valve with the selector control shaft.






8. Hook the detent arm spring (A) to the detent arm (B).






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





10. Install the reverse shift fork and the reverse selector together on the shift fork shaft and the countershaft subassembly. Secure the reverse shift fork to the shift fork shaft with the lock bolt and a new lock washer (E), then bend the lock tab of the lock washer against the bolt head.

11. Install the needle bearing and the countershaft reverse gear on the countershaft subassembly.

12. Install the reverse idler gear in the transmission housing A/T Housing Reverse Idler Gear Removal And Installation, if it was removed.

13. Install the idler gear shaft A/T Idler Gear Shaft Removal And Installation, if it was removed.

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





15. Align the spring pin (D) of the selector control shaft (E) with the transmission housing groove (F) by turning the selector control shaft. Do not squeeze the end of the selector control shaft tips together when turning the selector control shaft. If the tips are squeezed together, it will cause a faulty shift position signal or position due to the play between the selector control shaft and the transmission range switch.

16. Place the transmission housing (G) on the torque converter housing. Do not install the input shaft (mainshaft) speed sensor and the output shaft (countershaft) speed sensor before installing the transmission housing on the torque converter housing.

17. Use snap ring pliers to expand the snap ring of the secondary shaft bearing, push the transmission housing down to start the secondary shaft bearing through the snap ring. Then release the pliers. While rotating the reverse idler gear with a screwdriver, push down the transmission housing until it bottoms and the snap ring snaps in place in the secondary shaft bearing snap ring groove.






18. Check that the secondary shaft bearing snap ring (A) is seated in the bearing and the transmission housing groove, and check that the snap ring end gap (B) is 0-7 mm (0-0.28 in).





19. Install the transmission housing mounting bolts (K24Z6 engine 2WD: 19 bolts, except K24Z6 engine 2WD: 20 bolts) along with the transmission hanger and the harness clamp brackets (K24Z1 engine). Tighten the mounting bolts to 44 Nm (4.5 kg-m, 33 lb-ft) in two or more steps in a crisscross pattern.

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





21. Install a new O-ring (C) on the output shaft (countershaft) speed sensor (D), and install the output shaft (countershaft) speed sensor and the sensor washer (E) on the transmission housing.

22. Install a new O-ring (F) on the shift solenoid wire harness connector (G), and install the connector in the transmission housing.





23. Connect the shift solenoid valve connectors:

- RED wire connector to shift solenoid valve E.
- GRN wire connector to shift solenoid valve C.
- ORN wire connector to shift solenoid valve B.
- BLU wire connector to shift solenoid valve A.
- YEL, WHT, and WHT wire connector to shift solenoid valve D.

24. Install a new gasket (A) and the dowel pins (B), then secure the shift solenoid valve cover (C) with the bolts.