Part 1

Mainshaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.

Mainshaft:

2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, 40 x 63 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Check the axial clearance of the 3rd gear.

Mainshaft 3rd Gear Axial Clearance Inspection
1. Remove the mainshaft transmission housing bearing.
2. Install the thrust needle bearing (A), 3rd gear (B), needle bearing (C), thrust needle bearing (D), 40 x 63 mm thrust washer (E), 3rd/5th clutch (F) 5th gear collar (G), and transmission housing bearing (H) on the mainshaft (1). Do not install the O-rings during inspection.





3. Install the idler gear (J) on the mainshaft by a press, then install the conical spring washer (K) and locknut (L).
4. Tighten the locknut to 29 Nm (3.0 kgf-m, 22 lbf-ft).
5. Set the dial indicator (A) on the 3rd gear (B).





6. Lift the 3rd gear (A) up while holding the mainshaft, and use the dial indicator (B) to read the 3rd gear axial clearance.





7. Measure the 3rd gear axial clearance in at least three places while moving the 3rd gear. Use the average as the actual clearance.

Standard: 0.04 - 0.10 mm (0.002 - 0.004 in.)

8. If the clearance is out of standard, remove the 40 x 63 mm thrust washer and measure its thickness (A).





9. Select and install a new thrust washer, then recheck.





10. After replacing the thrust washer, make sure the clearance is within standard.
11. Disassemble the installed parts from the mainshaft.
12. Reinstall the bearing in the transmission housing.

Countershaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.

Countershaft:

2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, park gear, reverse selector, 33 x 45 x 7.8 mm collar, and gears in the direction shown.
6. Replace the locknut and conical spring washer with new ones when assembling the transmission. The countershaft locknut has left-hand threads.
7. Some reverse selector hubs are press-fitted to the countershaft; remove the hubs with a press, and install them with the special tool and a press.

Countershaft Reverse Selector Hub Removal
1. Remove the reverse selector hub from the countershaft by hand. If the reverse selector hub (A) cannot be removed by hand, it is press-fitted to the countershaft (B), and remove it from the countershaft with a press. Place the 4th-5th gear (C) on press bases (D), and place a shaft protector (E) between the countershaft and press to prevent damaging the countershaft.

NOTE: Some reverse selector hubs are not press-fitted, and can be removed without using a press.





2. Press the countershaft out of the press-fitted reverse selector hub, and remove the countershaft while holding the underside the countershaft. The countershaft falls down when pressing the countershaft out of the press-fitted reverse selector hub.
3. Remove the remaining parts from the countershaft, if necessary.

Countershaft Reverse Selector Hub Installation

Special Tools Required
Driver, 40 mm I.D. 07746-0030100

1. Install the 1st gear, 2nd gear, 3rd gear, 33.2 x 40 x 26 mm collar, 29 mm cotters, and 33 x 45 x 7.8 mm collar on the countershaft, and secure them with the snap ring.
2. Install the needle bearings and 4th-5th gear.
3. Slide the reverse selector hub (A) over the countershaft (B), then press it in place with the special tool and a press.

NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the special tool a press.





Secondary Shaft Disassembly, Inspection, and-Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.

Secondary Shaft:

2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, idler gear, and 31 x 54 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the axial clearance of the 1st gear and 2nd gear.
9. Inspect the condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them.

Secondary Shaft 1st Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), 1st gear (B), needle bearing (C), thrust needle bearing (D), 31 x 54 mm thrust washer (E), and 1st clutch (F) on the secondary shaft (G), then secure them with the snap ring (H).





2. Measure the clearance between the snap ring (A) and the 1st clutch drum (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance.





3. If the clearance is out of standard, remove the 31 x 54 mm thrust washer and measure its thickness (A).





4. Select and install a new thrust washer, then recheck.





5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the installed parts from the secondary shaft.

Secondary Shaft 2nd Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), needle bearing (B), 2nd gear (C), thrust needle bearing (D), 43 x 54.5 mm thrust washer (E), 39 mm cotters (F) and cotter retainer (G) on the secondary shaft (H), then secure them with the snap ring (I).





2. Set the! dial indicator (A) on the 2nd gear (B).





3. Lift the 2nd gear (A) up while holding the secondary shaft (B), and use the dial indicator (C) to read the 2nd gear axial clearance.





4. Measure the 2nd gear axial clearance in at least three places while turning the 2nd gear. Use the average as the actual clearance.

Standard: 0.04 - 0.12 mm (0.002 - 0.005 in.)

5. If the clearance is out of standard, remove the 43 x 54.5 mm thrust washer and measure its thickness.
6. Select and install a new thrust washer, then recheck.





7. After replacing the thrust washer, make sure the clearance is within standard.
8. Disassemble the installed parts from the secondary shaft.

Secondary Shaft Sealing Ring Replacement
The sealing rings are synthetic resin with chamfered ends. Check the condition of the sealing rings, and replace them only if they are worn, distorted, or damaged.

1. For a better fit, squeeze sealing rings together slightly before installing them.





2. Apply ATF to the new sealing rings, then install them on the mainshaft.





3. After installing the sealing rings, verify the following:
^ The rings are fully seated in the groove.
^ The rings are not twisted.
^ The chamfered ends of the rings are properly joined.

1st Clutch Disassembly
1. Remove the snap ring with a screwdriver.





2. Remove the clutch end-plate (A), clutch discs (B) (6), clutch waved-plates (C) (6), and waved spring (D) from the 1st clutch drum (E).





3. 1st clutch disassembly is complete. Do not remove the return spring retainer from the 1st clutch.

NOTE: The 1st clutch pack is included clutch pressure release pressure cavity between the spring retainer and clutch piston. The oil seal is installed on the circumference of the spring retainer, and contacts with the clutch piston. If you remove the spring retainer from the piston, it will damage to the oil seal when reinstalling the retainer in the piston.

2nd, 3rd, 4th, and 5th Clutch Disassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Remove the snap ring with a screwdriver.





2. Remove the clutch end-plate (A), clutch discs (B) (4), clutch flat-plates (C) (4), and waved spring (D) from the 2nd clutch drum (E).





3. Remove the clutch end-plate (A), clutch discs (B) (4), clutch flat-plates (C) (4), and waved spring (D) from the 4th clutch drum (E).





4. Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 3rd clutch drum (E).





5. Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 5th clutch drum (E).





6. Install the special tools.





7. Be sure the special tool (A) is adjusted to have full contact with the return spring retainer (B).





8. If either end of the special tool is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.





9. Compress the return spring until the snap ring can be removed.





10. Remove the snap ring with the snap ring pliers.





11. Remove the special tools.
12. Remove the snap ring (A), spring retainer (B), and return spring (C).





13. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other passage while applying air pressure.





14. Remove the clutch piston (A), and remove the outer O-ring (B) and inner O-ring (C) from the piston.