Diesel Data: Automotive Repair
Home >> Honda >> 1996 >> Accord Sedan V6-2.7L SOHC (24 Valve) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Transmission >> Overhaul >> Assemble

Assemble

LEFT COVER FEED PIPE INSTALLATION



1. Install the feed pipes in the left side cover with new O-rings, aligning the lugs with the grooves in the left side cover.
2. Install the snap rings.

PARKING BRAKE STOP
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.
Standard: 73.2 - 74.2 mm (2.88 - 2.92 inch)



3. If the measurement is out of tolerance, select and install the appropriate parking brake stop from the table.
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 value of the bolts:
- 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 the 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 main valve body with four 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 directions.




3. If the ATF pump drive gear and ATF pump driven gear shaft do not move freely, loosen the main valve body bolts, realign the ATF pump driven gear shaft, and then retighten to the specified torque.

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 stator shaft and stop shaft.
5. Install the two dowel pins, torque converter check valve and torque converter check valve spring in the main valve body.
6. Install the regulator valve body with the bolt on the main valve body.
7. Install the two dowel pins and separator plate on the regulator valve body, then install the lock-up valve body (seven bolts).
8. Install the secondary separator plate with two dowel pins on the main valve body.
9. Install the control shaft in the housing with the control shaft and manual valve together.




10. Install the detent arm and arm shaft in the main valve body, then hook the detent spring to the detent arm.
11. Install the secondary valve body, servo separator plate and servo body (seven bolts).
12. Install the 4th accumulator cover (three bolts).
13. Install the ATF strainer (two bolts).
14. Install the servo detent base (two bolts).
15. Install the accumulator body (seven bolts).
16. Install one ATF feed pipe in the main valve body, two ATF feed pipes in the servo body, two ATF feed pipes in the lock-up valve body and one oil feed pipe in the accumulator body.




17. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing.
18. Install the splined washer, thrust needle bearing and needle bearing on the secondary shaft.




19. Install the needle bearings, reverse selector hub, and reverse selector with the shift fork on the countershaft.
NOTE: Install the reverse selector hub and the reverse selector in the direction shown.




20. Turn the shift fork shaft so the large chamfered hole is facing the fork bolt hole. Then install the shim fork and the lock bolt with a new lock washer, and torque. Bend the lock tab against the bolt head.




21. Install the secondary shaft 2nd gear on the secondary shaft and the countershaft reverse gear on the countershaft. Then install the countershaft 2nd gear on the countershaft, and install the thrust needle bearing and thrust washer on the secondary shaft.




22. Measure the distance between the top of the secondary shaft and the thrust washer with a depth gauge.
Standard: 61.4 - 61.8 mm (2.42 - 2.43 inch)

NOTE: If the distance is not within the standard, the transmission cannot be assembled.

23. If the distance is out of the tolerance, check that 2nd gear engages with the clutch discs securely in the 2nd clutch assembly, then recheck.
If the distance is still out, remove the secondary shaft from the torque converter housing. Check that the 1st-hold clutch hub and secondary 1st clutch hub engage with their clutch discs in the lsV1st-hold clutch assembly, and that the parts are assembled correctly, then reinstall and recheck.




24. Install the thrust washer in the transmission housing as shown.




25. Install the reverse idler gear in the transmission housing as shown, then slide it the direction shown.




26. Align the control shaft spring pin with the transmission housing groove by turning the control shaft.
27. Install the dowel pins and a new gasket on the torque converter housing .
28. Place the transmission housing on the torque converter housing.




29. Install the transmission housing bolts along with the transmission hangers and harness bracket. Torque the bolts in two or more steps in the sequence shown.
Torque to 44 Nm (33 ft. lbs.)




30. Engage the reverse idler gear with the countershaft and mainshaft reverse gears. Then install the needle bearings, reverse idler gear shaft and thrust washer in the reverse idler gear, and install the reverse idler gear shaft holder on the transmission housing.




31. Install the parking brake lever on the control shaft, then install the lock bolt loosely with a new lock washer.
NOTE: Do not tighten the lock bolt to the specified torque and bend the lock tab in this step.




32. Slip the special tool onto the mainshaft.
33. Lubricate the following parts with ate:
- Splines and threads of each shaft.
- Threads of the old locknuts.
- Splines of the mainshaft and countershaft idler gears.
- Splines of the parking gear.
34. Install the mainshaft idler gear.




35. Install the old locknut on the mainshaft to seat the idler gear.
- Torque to 226 Nm (166 ft. lbs.)

NOTE:
- Do not drive the idler gear on with a hammer.
- Do not use an impact wrench; always use a torque wrench to tighten the locknut.

36. Install the secondary shaft idler gear on the secondary shaft.




37. Install the splined washer, thrust needle bearing, needle bearing, countershaft idler gear, thrust needle bearing, and parking gear on the countershaft.




38. Install the old locknut on the secondary shaft. Tighten the old locknut to seat the secondary shaft idler gear while holding the countershaft idler gear.
- Torque to 226 Nm (166 ft. lbs.)

NOTE:
- The secondary shaft locknut has left-hand threads.
- Do not drive the idler gear on with a hammer.
- Do not use an impact wrench; always use a torque wrench to tighten the locknut.




39. Install the parking brake pawl shaft and spring in the transmission housing, then install the parking brake pawl.
40. Place a 24 mm socket on the parking gear, and install a 10 x 1.25 mm bolt in the countershaft. Then engage the parking brake pawl with the parking gear by moving the parking brake pawl.




41. Tighten the bolt and lightly seat the parking gear.
NOTE: Do not drive the parking gear on with a hammer.

42. Remove the bolt and socket.
43. Use the old locknut to tighten the press-fit parking gear to the specified torque, then loosen it.
- Torque to 226 Nm (166 ft. lbs.)

NOTE:
- The countershaft locknut has left-hand threads.
- Do not use an impact wrench; always use a torque wrench to tighten the locknut.




44. Remove the old locknut, then install new conical spring washers and new locknuts on each shaft.

CAUTION: Install the conical spring washers in the direction shown.




45. Tighten the locknuts to specified torque using a torque wrench.
- Torque to 167 Nm (123 ft. lbs.)

NOTE:
- Do not use an impact wrench; always use a torque wrench to tighten the locknuts.
- The countershaft and secondary shaft locknuts have left-hand threads.
- Do not use an impact wrench; always use a torque wrench to tighten the locknut.




46. Stake each locknut into its shaft using a 3.5 mm punch.
47. Set the parking brake lever in the [P] position, then verify that the parking brake pawl engages the parking gear.
48. If the pawl does not engage fully, check the parking brake pawl stopper clearance.



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



50. Install the left side cover.
- Torque to 12 Nm (8.7 ft. lbs.)
51. Install the ATF cooler pipes with new sealing washers.
- Torque to 28 Nm (21 ft. lbs.)
52. Install the ATF dipstick.
53. Install the connectors on the connector bracket on the ATF cooler pipe, and install the harnesses to the clamp.
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