Shafts and Clutches, Disassemble & Service
Shafts and ClutchesMainshaft 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 the 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, the 40 x 63 mm thrust washer in the direction shown.
7. Replace the locknut and the 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), the 3rd gear (B), the needle bearing (C), the thrust needle bearing (D) the 40 x 63 mm thrust washer (E), the 3rd/5th clutch (F), the 5th gear collar (G), and the transmission housing bearing (H) on the mainshaft (I). 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 the 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 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 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 the shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, the park gear, the reverse selector, the 33 x 45 x 7.8 mm collar, and the gears in the direction shown.
6. Replace the locknut and the 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 removed 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, the 2nd gear, the 3rd gear, the 33.2 x 40 x 26 mm collar, the 29 mm cotters, and the 33 x 45 x 7.8 mm collar on the countershaft, and secure them with the snap ring.
2. Install the needle bearings and the 4th-5th gear.
3. Slide the reverse selector hub (A) over the countershaft (B), then press it in place using the driver (40 mm I.D.) and a press.
NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the 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 the 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, the idler gear, and the 31 x 54 mm thrust washer in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the axial clearance of 1st gear and the 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), the 1st gear (B), the needle bearing (C), the thrust needle bearing (D), the 31 x 54 mm thrust washer (E), and the 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), the needle bearing (B), the 2nd gear (C), the thrust needle bearing (D), the 43 x 54.5 mm thrust washer (E), the 39 mm cotters (F), and the 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 moving 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.
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), the clutch discs (B) (6), the clutch wave-plates (C) (6), and the wave spring (D) from the 1st clutch drum (E).
3. Remove the clutch end-plate (A), the clutch discs (B) (3), the clutch flat-plates (C) (3), and the wave spring (D) from the 2nd clutch drum (E).
4. Remove the clutch end-plate (A), the clutch discs (B) (4), the clutch flat-plates (C) (4), and the wave spring (D) from the 4th clutch drum (E).
5. Remove the clutch end-plate (A), the clutch discs (B) (3), the clutch wave-plates (C) (3), and the wave spring (D) from the 4th clutch drum (E).
6. Remove the clutch end-plate (A), the clutch discs (B) (3), the clutch wave-plates (C) (3), and the wave spring (D) from the 5th clutch drum (E).
7. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
8. Set the clutch spring compressor attachment (A) on the 1st clutch spring retainer (B) so the clutch spring compressor attachment works on the clutch return spring (C).
9. If either end of the clutch spring compressor attachment is not set over the clutch return spring end (A), reset the clutch spring compressor attachment over the return spring end.
10. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 2nd, 3rd, 4th, and 5th clutches.
11. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is unsupported by the return spring, reset the clutch spring compressor attachment over the proper position.
12. Compress the return spring until the snap ring can be removed.
13. Remove the snap ring with snap ring pliers.
14. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
15. Remove the snap ring (A), the spring retainer (B), and the return spring (C).
16. 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.
17. Remove the clutch piston (A), and remove the outer O-ring (B) and inner O-ring (C) from the piston.
Clutch Inspection
1. Inspect the clutch pistons and the clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. If the spring retainer is worn or damaged, replace it.
5. Check the oil seal (A) on the 1st clutch spring retainer for wear, damage, and peeling.
6. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
7. Inspect the clutch discs, the clutch plates, and the clutch end-plate for wear, damage, and discoloration.
Clutch Discs Standard Thickness
1st clutch: 1.94 mm (0.076 in.)
2nd clutch: 1.96 mm (0.077 in.)
3rd clutch: 1.94 mm (0.076 in.)
4th clutch: 1.96 mm (0.077 in.)
5th clutch: 1.94 mm (0.076 in.)
Clutch Plates Standard Thickness
1st clutch (wave-plates): 1.6 mm (0.063 in.)
2nd clutch (flat-plates): 2.3 mm (0.091 in.)
3rd clutch (wave-plates): 2.0 mm (0.079 in.)
4th clutch (flat-plates): 1.6 mm (0.063 in.)
5th clutch (wave-plate): 2.0 mm (0.079 in.)
8. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clearance between the clutch end-plate and the top disc.
9. If any flat-plate is worn, damaged, or discolored, replace them as a set. if the clutch flat-plates are replaced, inspect the clearance between the clutch end-plate and the top disc.
10. If any wave-plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the other wave-plates for a phase difference. If the clutch wave-plate is replaced, inspect the clearance between the clutch end-plate and the top disc.
11. If the clutch end-plate is worn, damaged, or discolored, inspect the clearance between the clutch end-plate and the top disc, then replace the clutch end-plate.
Clutch Wave-plate Phase Difference Inspection
1. Place the clutch wave-plate (A) on a surface plate, and set a dial indicator (B) on the wave-plate.
2. Find the bottom (D) of a phase difference of the wave-plate, zero the dial indicator, and make a reference mark on the bottom of the wave-plate.
3. Rotate the 1st clutch wave-plate 5 or 6 tooth of angles apart from the bottom while holding the wave-plate by its circumference, and rotate the 3rd and 5th clutch wave-plate about 60-degrees apart from the bottom while holding the wave-plate by its circumference. The dial indicator should be at the top (E) of a phase difference. Do not rotate the wave-plate while holding its surface, always rotate it by holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the wave-plate between the bottom and top.
Standard: 0.07 - 0.20 mm (0.003 - 0.008 in.)
5. Rotate the 1st clutch wave-plate 5 or 6 tooth of angles from the top, and rotate the 3rd and 5th clutch wave-plate about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and H). Zero the dial indicator.
6. Measure the phase difference at the other two tops (G and I) of the wave-plate by following steps 3 thru 5.
7. If two of the three measurements are within the standard, the wave-plate is OK. If two of the three measurements are out of the standard, replace the wave-plate.
Clutch Clearance Inspection
Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100
1. Inspect the clutch piston, the discs, the plates, and the end-plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.
2. Install the clutch piston in the clutch drum. Do not install the O-rings on the clutch piston during inspection.
3. Install the wave spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
4. Install the wave spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
5. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
6. Install the wave spring (A) in the 3rd clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
7. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
8. Install the snap ring with a screwdriver to secure the clutch end-plate.
9. Set a dial indicator (A) on the clutch end-plate (B).
10. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).
11. Release the clutch end-plate to lower it, then put the clutch compressor attachment on the end-plate (A).
12. For the 1st, 3rd, and 5th clutches:
Press the clutch compressor attachment down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
13. For 2nd and 4th clutches:
Press the clutch compressor attachment down with 39 N (4 kgf, 9 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
Clearance between Clutch End-Plate and Top Disc
Service Limit
1st clutch: 1.62 - 1.82 mm (0.064 - 0.072 in.)
2nd clutch: 0.5 - 0.7 mm (0.020 - 0.028 in.)
3rd clutch: 0.73 - 0.93 mm (0.029 - 0.037 in.)
4th clutch: 0.7 - 0.9 mm (0.028 - 0.035 in.)
5th clutch: 0.73 - 0.93 mm (0.029 - 0.037 in.)
14. If the clearance of the 1st, 3rd, or 5th clutch is out of the service limit, select a new clutch end-plate from the following table.
15. If the clearance of the 2nd or 4th clutch is out of the service limit, remove the clutch end-plate and check the clutch end-plate mark. Select a new clutch end-plate from the following tables by the mark on the old clutch end-plate. Use the AC-AL Plates table when the old clutch end-plate is marked with between AC and AL. Use the AM-AV Plates table when the old clutch end-plate is marked with between AM and AV.
16. Install the new clutch end-plate and recheck the clearance. If the thickest clutch end-plate is installed but the clearance is still over the service limit, replace the clutch discs and plates.
Clutch Reassembly
Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
NOTE: Coat all parts with ATF during reassembly.
1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
2. Install the new O-rings (A) on the clutch piston (B).
3. Install the clutch piston (A) in the clutch drum (B) while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.
4. Install the return spring (A) and the spring retainer (B), and position the snap ring (C) on the spring retainer.
5. Install the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
6. Set the clutch spring compressor attachment (A) on the 1st clutch spring retainer (B) so the clutch spring compressor attachment works on the clutch return spring (C).
7. If either end of the clutch swing compressor attachment is not set over the clutch return spring end (A), reset the clutch spring compressor attachment over the return spring end.
8. Be sure the clutch spring compressor attachment (A) is adjusted to have full contact with the spring retainer (B) on the 2nd, 3rd, 4th, and 5th clutches.
9. If either end of the clutch spring compressor attachment is set over an area of the spring retainer that is unsupported by the return spring, reset the clutch spring compressor attachment over the proper position.
10. Compress the return spring until the snap ring can be installed.
NOTE: Compress the 1st clutch return spring gently, and install the spring retainer to ensure proper seating in the 1st clutch piston. Do not pinch the oil seal.
11. Install the snap ring with snap ring pliers.
12. Remove the clutch spring compressor attachments and the clutch spring compressor bolt assembly.
13. Install the wave spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (6) and discs (D) (6). Install the clutch end-plate (E) with the flat side down on the top disc.
14. Install the wave spring (A) in the 2nd clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
15. Install the wave spring (A) in the 4th clutch drum (B). Starting with the clutch flat-plate, alternately install the flat-plates (C) (4) and the discs (D) (4). Install the clutch end-plate (E) with the flat side down on the top disc.
16. Install the wave spring (A) in the 3rd clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
17. Install the wave spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the wave-plates (C) (3) and the discs (D) (3). Install the clutch end-plate (E) with the flat side down on the top disc.
18. Install the snap ring with a screwdriver to secure the clutch end-plate.
19. Check that the clutch piston moves by applying air pressure into the fluid passage.