Transmission Housing Disassemble & Service
Housing and Shaft Assembly RemovalSpecial Tools Required
Housing puller 07HAC-PK40102
1. Remove the shift solenoid valve cover (A), the dowel pins (B). the gasket (C), and the harness clamp bracket (D).
2. Disconnect the connectors from the shift solenoid valves, and remove the solenoid harness connector (E).
3. Remove the transmission housing mounting bolts (F) (19).
4. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C) by turning the selector control shaft with the detent plate.
5. Install the housing puller over the countershaft, then remove the transmission housing.
NOTE: If the top arm of your housing puller is too short, replace it with housing puller arm, 205 mm 07SAC-P0Z0101.
6. Remove the countershaft reverse gear and the needle bearing.
7. Remove the lock bolt securing the shift fork, then remove the shift fork with the reverse selector together.
8. Remove the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly (C) together. If the reverse selector hub is removed by hand, remove the 4th-5th gear and the needle bearings, and remove the mainshaft subassembly. Then remove the countershaft subassembly and the secondary shaft subassembly together.
9. Remove the differential assembly.
Bearing Removal
Special Tools Required
^ Attachment, 72 x 75 mm 07746-0010600
^ Attachment, 78 x 80 mm 07NAD-PX40100
^ Attachment, 62 x 68 mm 07746-0010500
^ Driver 07749-0010000
1. Remove the snap ring (A), the cotter retainer (B), and the cotters (C) from the idler gear shaft (D), then remove the idler gear shaft. Do not distort the snap ring.
2. To remove the mainshaft bearing (A), the countershaft bearing B, the secondary shaft bearing (C), and the idler gear shaft bearing (D) from the transmission housing, expand each snap ring using snap ring pliers, then push the bearing out using the driver and the attachment.
Bearing Installation
Special Tools Required
^ Attachment, 72 x 75 mm 07746-0010600
^ Attachment, 78 x 80 mm 07NAD-PX40100
^ Attachment, 62 x 68 mm 07746-0010500
^ Driver 07749-0010000
1. Install the mainshaft bearing (A), the countershaft bearing B, the secondary shaft bearing (C), and the idler gear shaft bearing (D) in the transmission housing in the direction shown.
2. Expand each snap ring using snap ring pliers, and install the bearing part-way into the housing.
3. Release the pliers, then push the bearing down into the housing using the driver and the attachment until the snap ring snaps in place around it.
4. After installing the bearings check that the snap rings (A) are seated in the bearing and housing grooves, and that the ring end gaps B, are 0 - 7 mm (0 - 0.28 in.)
5. Install the idler gear shaft (A) in the idler gear shaft bearing.
6. Install the cotters (B) and the cotter retainer (C), and secure the idler gear shaft with the snap ring (D).
Reverse Idler Gear Removal
1. Remove the bolts (A) securing the reverse idler gear shaft holder (B).
2. Install a 5 x 0.8 mm bolt (C) in the reverse gear shaft, and pull it to remove the reverse idler gear shaft (D) and the reverse idler gear shaft holder together.
3. Remove the reverse idler gear.
Reverse Idler Gear Installation
1. Lightly coat the reverse idler gear shaft (A), the needle bearing (B), and new O-rings (C) with lithium grease.
2. Assemble new O-rings and needle bearing on the reverse idler gear shaft, then install the reverse idler gear shaft in the reverse idler gear shaft holder (D). Align the D-shaped (E) cut out of the shaft with the D-shaped area (F) of the holder.
3. Install the reverse idler gear in the transmission housing in the direction shown.
4. Install the reverse idler gear shaft/holder assembly in the reverse idler gear.
5. Secure the holder with the bolts.
Idler Gear Shaft Removal and Installation
1. Remove the snap ring (A), the cotter retainer (B), and the coffers (C) from the idler gear shaft (D), then remove the idler gear shaft. Do not distort the snap ring.
2. Check the snap ring and the coffer retainer for wear and damage. Replace the snap ring and/or the cotter retainer if the snap ring or the cotter retainer is worn, distorted, or damaged.
3. Install the idler gear shaft in the idler gear shaft bearing.
4. Install the cotters and the cotter retainer, and secure the idler gear shaft with the snap ring.
Shaft Assembly and Housing Installation
1. Install the spacer in the torque converter housing with the spacer tab into the guide of the torque converter housing. Do not mix-up the spacers from the transmission housing and the torque converter housing. Install the differential assembly in the torque converter housing, and put the spacer on the differential.
Housing And Shaft Assemblies:
2. Install the differential assembly securely in the torque converter housing so there is no clearance.
3. Install the 90 mm thrust shim in the transmission housing.
4. Assemble the mainshaft, the countershaft, and the secondary shaft.
^ Countershaft reverse selector hub is press-fitted type, go to step 5.
^ Countershaft reverse selector hub is not press fitted type, go to step 6.
5. Join the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly (C) together, and install them in the torque converter housing.
6. Join the countershaft subassembly and the secondary shaft subassembly together, then install them in the torque converter housing, and install the mainshaft subassembly. Install the needle bearings, 4th-5th gear, and the reverse selector hub over the countershaft.
7. Turn the shift fork shaft (A) so the large chamfered hole (B) is facing the fork bolt hole (C) of the shift fork (D).
8. Install the shift fork and the reverse selector together on the shift fork shaft and the countershaft. Secure the 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.
9. Install the needle bearing and the countershaft reverse gear on the countershaft.
10. Install the reverse idler gear in the transmission housing.
11. Install the three dowel pins (A) and a new gasket (B) on the torque converter housing (C).
12. Align the spring pin (D) of the control shaft (E) with the transmission housing groove (F) by turning the selector control shaft detent plate. Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together, it will causes a faulty shift position signal or position due to the play between the selector control shaft and the switch.
13. 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.
14. Wrap a screwdriver tip with tape to prevent damage to the reverse idler gear teeth. Engage the reverse idler gear with the reverse gears by rotating the idler gear using the screwdriver.
15. Install the transmission housing mounting bolts, and tighten the 19 bolts to 44 N-m (4.5 kgf-m, 33 lbf-ft) in two or more steps in a crisscross pattern.
16. Install the shift solenoid harness connector (E) in the transmission housing with a new O-ring (F)
17. Connect WHT harnesses and ORN harness connector to shift solenoid valve B. ATF temperature sensor is assembled in the connector with WHT harnesses.
18. Connect the shift solenoid harness connectors:
^ BLU wire to shift solenoid valve A.
^ GRN wire to shift solenoid valve C.
^ YEL wire to shift solenoid valve D.
19. Install the shift solenoid valve cover (A), the two dowel pins (B), a new gasket (C), and the harness clamp bracket (D).
