Housing and Shaft Assemblies Removal/Installation
Housing and Shaft Assemblies Removal
- Special Tools Required
- Housing puller 07HAC-PK40102
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Remove the ATF dipstick guide pipe.
2. Remove the two bolts securing the reverse idler gear shaft holder, then remove the reverse idler gear shaft holder (A), shaft (B), and washer (C).
3. Remove the transmission housing mounting bolts, transmission hangers, and harness clamp bracket.
4. Move the reverse idler gear (A) to disengage it from the mainshaft and countershaft reverse gears.
NOTE: The transmission housing will not separate from the torque converter housing if the reverse idler gear is not moved.
5. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (C) by turning the control shaft.
6. Install the special tool over the mainshaft, then remove the transmission housing (D).
NOTE: If the top arm of your housing puller is too short, replace it with Housing Puller Arm, 205 mm, T/N 07SAC-P0Z0101.
7. Remove the reverse idler gear, needle bearings, and thrust washer from the transmission housing.
8. Remove the countershaft 2nd gear, then remove the countershaft reverse gear and the needle, bearing.
9. Remove the lock bolt securing the shift fork, then remove the shift fork with the reverse selector. If the reverse selector hub is not press-fitted, remove the reverse selector hub, countershaft 5th gear, and needle bearing from the countershaft.
10. Remove the secondary shaft sub-assembly. If the reverse selector hub is press-fitted, remove the secondary shaft sub-assembly, countershaft subassembly and mainshaft sub-assembly together.
11. Remove the countershaft sub-assembly.
12. Remove the mainshaft sub-assembly.
13. Remove the differential assembly.
14. Remove the countershaft speed sensor if necessary.
Bearing Removal and Installation
- Special Tools Required
- Driver 07749-0010000
- Seal driver attachment 07GAD-PG40101
- Attachment, 62 x 68 mm 07746-0010500
- Attachment, 72 x 75 mm 07746-0010600
NOTE: Coat all parts with ATF before assembly.
1. To remove the mainshaft bearing (A), countershaft bearing (B), and secondary shaft bearing (C) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out.
NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing.
2. Install the bearings in the direction shown.
3. Expand each snap ring with the snap ring pliers, and insert the bearing part-way into the housing.
4. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
5. After installing the bearings verify the following:
- The snap rings (A) are seated in the bearing and housing grooves.
- The ring end gaps (B) are correct.
Shaft Assemblies and Housing Installation
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing.
2. Install the countershaft 5th gear and reverse selector hub on the countershaft. If the reverse selector hub is a press-fitted type, refer to the installation.
3. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole. Then install the shift fork (B) and reverse selector (C) together on the shift fork shaft and countershaft (D). Secure the shift fork to the shift fork shaft with the lock bolt (E) and a new lock washer (F), then bend the lock washer against the bolt head.
4. Install the needle bearing, countershaft reverse gear, and countershaft 2nd gear on the countershaft.
5. Place the thrust washer (A) in the transmission housing.
6. Place the reverse idler gear (A) in the transmission housing, then slide it in the direction shown.
7. Align the spring pin (A) on the control shaft (B) with the transmission housing groove (C) by turning the control shaft.
8. Install three dowel pins and a new gasket on the torque converter housing.
9. Place the transmission housing on the torque converter housing, then install the transmission housing mounting bolts along with the harness clamp bracket (A) and transmission hangers (B). Tighten the bolts in two or more steps in a crisscross pattern.
TORQUE: 44 Nm (4.5 kgf-m, 33 ft. lbs.)
10. Engage the reverse idler gear with the countershaft reverse gear and the mainshaft reverse gear. Then install the needle bearings (A), reverse idler gear shaft (B), and thrust washer (C) in the reverse idler gear, and install the reverse idler gear shaft holder (D) on the transmission housing.