Transmission End Cover Disassemble & Service

End Cover Removal

Special Tools Required
Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100

1. Remove the ATF dipstick.
2. Remove the five bolts (D) securing the ATF inlet line brackets, the ATF filter bracket bolts (E), the line bolt and the sealing washers, and remove the ATF inlet line, the ATF hose, and the ATF filter (F).

End Cover:

3. Remove the ATF outlet line bolt, the line mounting bolt, the sealing washers, and the ATF outlet line (G).
4. Remove A/T clutch pressure control solenoid valve A, the ATF joint pipes, the O-rings, the ATF pipe, and the gasket.
5. Remove A/T clutch pressure control solenoid valves B and C, the O-rings, the ATF pipe, the ATF joint pipes, and the gasket.
6. Remove the input shaft (mainshaft) speed sensor (H) and the output shaft (countershaft) speed sensor (I).
7. Remove the ATF warmer bracket (J).
8. Remove the transmission range switch cover (K).
9. Remove the transmission range switch harness clamps (L) from the clamp bracket (M), then remove the transmission range switch (N).
10. Remove the clamp bracket from the end cover (O).
11. Remove the end cover, the dowel pins, the O-rings, and the end cover gasket.
12. Remove the ATF lubrication pipe (P) from the idler gear shaft.
13. Slip the mainshaft holder onto the mainshaft.





14. Engage the park pawl with the park gear.
15. Cut the lock tab (A) of the each shaft locknut (B) using a chisel (C). Then remove the locknuts and conical spring washers from each shaft.





16. Remove the snap ring securing the idler gear to the idler gear shaft.
17. Install 6 x 1.0 mm bolts (A) on the idler gear shaft idler gear (B). Set a puller (C) on the idler gear shaft (D) with putting a spacer (E) between the puller and the idler gear shaft, then remove the idler gear shaft idler gear.





18. Set the puller, 6 x 1.0 mm bolts, and spacer on the secondary shaft idler gear (F) and remove the secondary shaft idler gear from the secondary shaft in the same manner as the removal of the idler gear shaft idler gear.
19. Set the puller, 6 x 1.0 mm bolts, and spacer on the mainshaft idler gear (G), and remove the mainshaft idler gear from the mainshaft in the same manner as the removal of the idler gear shaft idler gear.
20. Set the puller, 6 x 1.0 mm bolts, and spacer on the park gear (H), and remove the park gear from the countershaft in the same manner as the removal of the idler gear shaft idler gear.
21. Remove the park pawl, the park pawl spring, the park pawl shaft, and the stop shaft.
22. Remove the park lever from the selector control shaft.

Park Lever Stop Inspection and Adjustment

1. Set the park lever in the P position.
2. Measure the distance (A) between the park pawl shaft center (B) and the extension line (C) connected centers of the park lever roller pin (D) and the control shaft (E) in the vertical direction from the extension line.





3. If the measurement is out of standard, select and install the appropriate park lever stop (A) from the table.





4. After replacing the park lever stop, make sure the distance is within tolerance.

Idler Gear Shaft Bearing Replacement

Special Tools Required
^ Adjustable bearing puller, 25 - 40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 52 x 55 mm 07746-0010400

1. Remove the idler gear shaft bearing from the end cover using the adjustable bearing puller and a commercially available 3/8" - 16 slide hammer (A).





2. Install a new bearing in the end cover using the driver and the 52 x 55 mm attachment.





Selector Control Shaft Oil Seal Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 22 x 24 mm 07746-0010800

1. Remove the oil seal from the end cover.





2. Install a new oil seal flush to the end cover using the driver and the 22 x 24 mm attachment.





Selector Control Shaft Bearing Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 22 x 24 mm 07746-0010800

1. Remove the oil seal from the end cover.





2. Remove the selector control shaft bearing from the end cover.





3. Install a new bearing flush to the end cover using the driver and the 22 x 24 mm attachment.





4. Install a new oil seal flush to the end cover using the driver and the 22 x 24 mm attachment.





ATF Feed Pipe Replacement

1. Remove the snap ring (A), the 3rd clutch feed pipe (B), and the feed pipe flange (C) from the end cover (D).





2. Install a new O-ring (E) over a new 3rd clutch feed pipe.
3. Install the 3rd clutch feed pipe in the end cover by aligning the feed pipe tabs (F) with the indentations in the end cover.
4. Install a new O-ring (G) in the end cover, then install the feed pipe flange over the 3rd clutch feed pipe.
5. Secure the 3rd clutch feed pipe and the feed pipe flange with the snap ring.
6. Remove the snap ring (H) and feed pipe flange (I).
7. Check the 4th clutch feed pipe (J) and 2nd clutch feed pipe (K) for scoring and damage. Replace the end cover, if the feed pipes are scored or damaged.
8. Install a new O-ring (L) over a new 4th clutch feed pipe.
9. Install a new O-ring (M) in the end cover, then install the feed pipe flange over the 4th clutch feed pipe.
10. Secure the 4th clutch feed pipe and feed pipe flange with the snap ring.

Transmission Fluid Pressure Switch Replacement

1. Remove the 2nd clutch transmission fluid pressure switch (A).





2. Make sure there is no water, oil, dust, or foreign particles inside the connector.
3. Install a new 2nd clutch transmission fluid pressure switch and a new sealing washer (B), then tighten the switch to the specified torque on the metal part, not the plastic part.
4. Remove the 3rd clutch transmission fluid pressure switch (C).
5. Make sure there is no water, oil, dust, or foreign particles inside the connector.
6. Install a new 3rd clutch transmission fluid pressure switch and a new sealing washer (D), then tighten the switch to the specified torque on the metal part, not the plastic part.

Air Check Valve Inspection and Replacement

1. Check the air check valve filter for clogging. If the filter is clogged, remove the air check valve (A), and clean the filter thoroughly by pouring clean ATF. Do not blow out the filter with compressed air. Replace the air check valve, if the filter or check valve (ball) is clogged or damaged.





2. Install the air check valve and a new sealing washer (B).

End Cover Installation

Special Tools Required
^ Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100
^ Gear installer set 070AC-XFD0100

1. Install the mainshaft holder onto the mainshaft.





2. Lubricate the following parts with ATF:

^ Splines and threads of the mainshaft.
^ Splines of the mainshaft idler gear.
^ Old conical spring washer and old locknut.

3. Install the mainshaft idler gear (A), the old conical spring washer (B), and the old locknut (C) on the mainshaft (D), and tighten the locknut to 216 N-m (22.0 kgf-m, 159 lbf-ft).





4. Lubricate the following parts with ATF:

^ Splines and threads of the secondary shaft and the idler gear shaft.
^ Splines of the secondary shaft idler gear.
^ Old conical spring washer and old locknut.

5. Install the secondary shaft idler gear (A) on the secondary shaft (B), and install the idler gear shaft idler gear (C) on the idler gear shaft (D).





6. Set the gear installer set on the idler gear shaft and the idler gear, and tighten the installer nut to install the idler gear part-way.





7. Install the old conical spring washer (A) and the old locknut (B) on the secondary shaft (C), and tighten the locknut to 226 N-m (23.0 kgf-m, 166 lbf-ft).





8. Retighten the installer nut to seat the idler gear in the idler gear shaft until it stops. Remove the gear installer set from the idler gear shaft.





9. Install a new snap ring (A) on the idler gear shaft (B), and check that the snap ring is seated securely into the groove.





10. Install the park lever (A) and the park lever stop (B) on the selector control shaft (C), then install the lock bolt and a new lock washer (D). Do not bend the lock tab of the lock washer until step 23.





11. Install the park pawl shaft (E), the park pawl spring (F) the park pawl (G), and the stop shaft (H) on the transmission housing.
12. Lubricate the following parts with ATF:

^ Threads and splines of the countershaft.
^ Old conical spring washer and old locknut.
^ Areas where the park gear contacts the conical spring washer.

13. Install the park gear (I), the old conical spring washer (A and the old locknut (K) on the countershaft.
14. Lift the park pawl up, and engage it with the park gear, then tighten the locknut to 226 N-m (23.0 kgf-m, 166 lbf-ft).

NOTE:
^ Do not tap the park gear to install.
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ Countershaft locknut has left-hand threads.

15. Remove the locknuts and the conical spring washers from the mainshaft, the countershaft, and the secondary shaft.
16. Lubricate the threads of the shafts, the new locknuts; and the new conical spring washers with ATF.
17. Install new conical spring washers (A) (B) with facing stamped mark side up in the direction shown, and install a new mainshaft locknut (C), a new countershaft locknut (D), and a new secondary shaft locknut (E).





18. Tighten the countershaft locknut and the secondary shaft locknut to 167 N-m (17.0 kgf-m, 123 lbf-ft), and tighten the mainshaft locknut to 155 N-m (15.8 kgf-m, 114 lbf-ft).

NOTE:
^ Be sure to install the conical spring washers in the direction shown.
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ Countershaft and secondary shaft locknuts have left-hand threads.

19. Remove the mainshaft holder from the mainshaft.
20. Stake the locknuts; into the shafts to a depth (A) of 0.7 - 1.3 mm (0.03 - 0.05 in.) using a 3.5 mm punch (B).





21. Set the park pawl (A) in the P position, then check that the park pawl engages with the park gear (B).





22. If the park pawl does not engage fully, check the distance (C) between the park pawl shaft and the extension line connected centers of the park lever roller pin and the selector control shaft.
23. Tighten the lock bolt (D), and bend the lock tab of the lock washer (E) against the bolt head.
24. Install the ATF lubrication pipe (A) into the idler gear shaft (B).





25. Install a new gasket (C) on the transmission housing, and install the two dowel pins (D) and new O-rings (E) over the top of the ATF feed pipes (F)
26. Install the end cover (G), and tighten the 17 bolts.
27. Set the selector control shaft (A) to the N position by turning the selector control shaft on the torque converter side.





28. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 in.) feeler gauge blade (D) in the cutouts to hold the switch in the N position.





29. Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position with the 2.0 mm (0.08 in.) blade (C).





30. Tighten the bolts on the transmission range switch while you continue to hold it in the N position. Do not move the transmission range switch while tightening the bolts. Remove the feeler gauge.





31. Install the harness clamp bracket (A) on the end cover (B).





32. Connect the transmission range switch connector (C) securely, then install the harness clamps (D) on the clamp bracket.
33. Install the transmission range switch cover (E).
34. Install a new O-ring (A) on the input shaft (mainshaft) speed sensor (B), then install the input shaft (mainshaft) speed sensor.





35. Install a new O-ring (C) on the output shaft (countershaft) speed sensor (D), then install the output shaft (countershaft) speed sensor.
36. Install a new gasket (B) on the transmission housing, and install the ATF pipe (C) and the ATF joint pipes (D).





37. Install new O-rings (E) over the ATF joint pipes, and install A/T clutch pressure control solenoid valve A.
38. Install a new gasket (A) with facing the blue side to the transmission housing and the white side faces to the A/T clutch pressure control solenoid valve body.





39. Install the ATF pipe (D) and the ATF joint pipes (E), and install new O-rings (F) over the ATF joint pipes.
40. Install A/T clutch pressure control solenoid valves B and C.
41. Install the ATF warmer bracket.





42. Install the ATF outlet line (A) on the torque converter housing, and secure it with the line bolt (B) and new sealing washers (C).





43. Secure the ATF outlet line with the bracket bolt.
44. Install the transmission hanger (A).





45. Install the ATF filter bracket (B).
46. Install the ATF inlet line and the hose (C) on the torque converter housing, and secure it with the line bolt (D) and new sealing washers (E).
47. Put the ATF filter (F) on its bracket, and secure with the bracket (G) and the bolt.
48. Secure the line brackets (H) with the bolts on the transmission hanger and the torque converter housing.
49. Install the breather cap on the breather pipe.
50. Install the ATF dipstick.