End Cover and Idler Gear Removal/Installation

End Cover, 3rd Gears, Idler Gear, and 3rd Clutch Removal

- Special Tools Required
- Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100
- Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Remove the ATF temperature sensor connector from the connector bracket, then disconnect the connector.
2. Remove the ATF temperature sensor harness clamp bolts and the ATF temperature sensor, then remove the switch cover.
3. Remove the A/T wire harness ground terminal from the connector bracket, and disconnect the 3rd clutch pressure switch connector, then remove the connector bracket.
4. Remove the transmission range switch cover.
5. Remove the transmission range switch harness clamp bolts and harness clamp, then remove the transmission range switch.
6. Remove the harness clamp bracket, ATF cooler line bolts (two), and lines.
7. Remove the line bolt, the ATF hose, and the ATF filter line.
8. Remove the ATF filter line bracket and ATF filter. Remove the ATF passage body if necessary.
9. Remove the A/T clutch pressure control solenoid valve C.
10. Remove the remaining 10 bolts on the end cover, then remove the end cover.





11. Slip the special tool onto the mainshaft.
12. Engage the park pawl with the park gear.





13. Cut the lock tabs (A) of each shaft locknut (B) using a chisel (C). Then remove the locknuts and conical spring washers from each shaft.

NOTE:
- Countershaft and secondary shaft locknuts have left-hand threads.
- Clean the old locknut; they are used to install the press fit mainshaft 3rd gear, secondary shaft idler gear, park gear, and 3rd clutch assembly on the countershaft.
- Keep all of the chiseled particles out of the transmission.

14. Remove the special tool from the mainshaft.





15. Remove the 3rd clutch assembly using the special tool and a commercially available 3/8-16" slide hammer (A).
16. Remove the splined washer, thrust needle bearing, countershaft 3rd gear, needle bearing, and thrust needle bearing from the countershaft.





17. Remove the mainshaft 3rd gear (A), secondary shaft idler gear (B), and park gear (C) with a puller (D).
18. Remove the park pawl, park pawl spring, park pawl shaft, and stop shaft.
19. Remove the park lever from the control shaft.
20. Remove A/T clutch pressure control solenoid valves A and B.

Park Lever Stop Inspection and Adjustment





1. Set the park lever (A) in the P position.
2. Measure the distance (B) between the park pawl shaft (C) and the park lever roller pin (D).
STANDARD: 84.6 - 85.6 mm (3.33 - 3.37 inch)





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





PARK LEVER STOP

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

Control Shaft Oil Seal Replacement

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





1. Remove the oil seal (A) from the end cover (B).





2. Install the new oil seal flush to the end cover with the special tools.

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, then remove the bearing.





2. Install the new bearing flush to the end cover with the special tools.
3. Install the new oil seal.

ATF Feed Pipes Replacement





1. Remove the snap rings (A), ATF feed pipes (B) and feed pipe flanges (C) from the end cover (D).
2. Install the new O-ring (E) over the ATF feed pipe.
3. Install ATF feed pipe in the end cover with aligning the feed pipe tabs with the indentations in the end cover.
4. Install the new O-ring (F) in the end cover, then install the feed pipe flange over the ATF feed pipe and O-rings.
5. Secure the ATF feed pipe and feed pipe flange with the snap ring.

End Cover, 3rd Gears, Idler Gear, and 3rd Clutch Installation

- Special Tools Required
- Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100
- Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A





1. Install the park lever (A) and park lever stop (B), on the control shaft (C), then install the lock bolt (D) with a new lock washer (E). Do not bend the lock tab of the lock washer until step 28.
2. Lubricate the following parts with ATF:
- Splines of the countershaft, the park gear, and the old locknut.
- Threads of the countershaft and the old locknut.
- Old conical spring washer.





3. Install the park gear (A) using the old locknut (B) and a collar (C). Hold the park pawl (D) against the park gear, then tighten the old locknut until the shaft splines come out over the park gear splines.

NOTE:
- Do not use an impact wrench.
- Countershaft locknut has left-hand threads.

4. Remove the locknut and collar.





5. Install the thrust needle bearing (A), needle bearing (B), 3rd gear (C), thrust needle bearing (D), 31 x 63.5 mm splined washer (E), 3rd clutch assembly (F), and old conical spring washer (G) on the countershaft (H). Tighten the old locknut (I) to 226 Nm (23.0 kgf-m, 166 ft. lbs.).

NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.





6. Set the dial indicator (A) to the countershaft 3rd gear (B).





7. Measure the countershaft 3rd gear axial clearance in at least three places, while moving the countershaft 3rd gear (A). Use the average as the actual clearance. If the clearance is out of standard, select the appropriate 31 x 63.5 mm splined washer in step 16.
STANDARD: 0.015 - 0.045 mm (0.0006 - 0.0018 inch)
8. Remove the locknut and conical spring washer.





9. Remove the 3rd clutch assembly (A) with the special tool and a commercially available 3/16" slide hammer (B).
10. Remove the parts that were installed in step 5.





11. Install the special tool onto the mainshaft.
12. Lubricate the following parts with ATF:
- Splines of the mainshaft 3rd gear and secondary shaft idler gear.
- Threads of the mainshaft and secondary shaft.
- Threads of the old mainshaft and secondary shaft locknuts.
- Old conical spring washer.





13. Install the mainshaft 3rd gear (A) and the old conical spring washer (B) on the mainshaft (C). Tighten the old locknut (D) to seat the 3rd gear to 226 Nm (23.0 kgf-m, 166 ft. lbs.).

NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.

14. Install the secondary shaft idler gear (E) and the old conical spring washer (F) on the secondary shaft (G). Tighten the old locknut (H) to seat the secondary shaft idler gear to 226 Nm (23.0 kgf-m, 166 ft. lbs.).

NOTE:
- Use a torque wrench to tighten the locknut. Do not use an impact wrench.
- Secondary shaft locknut has left-hand threads.

15. Remove the old locknuts and old conical spring washers from the mainshaft and secondary shaft.





16. If the 3rd gear axial clearance is out of standard (measured in step 7), measure the difference of the 31 x 63.5 mm splined washer, and select the appropriate splined washer from the table.





SPLINED WASHER, 31 X 63.5 mm

17. Install the thrust needle bearing (A), needle bearing (B), 3rd gear (C), thrust needle bearing (D), and 31 x 63.5 mm splined washer (E) on the countershaft (F).
18. Wrap the shaft splines with tape to prevent O-ring damage, then install new O-rings (G).





19. Remove the tape, then install the 3rd clutch assembly (H), and old conical spring washer (I). Tighten the old locknut (J) to 226 Nm (23.0 kgf-m, 166 ft. lbs.).

NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.

20. Remove the old locknut and old conical spring washer from the countershaft.
21. Lubricate the threads of each shaft, the new locknuts, and new conical spring washers with ATF.





22. Install the new conical spring washers (A) in the direction shown, and install the new locknuts (B).
23. Tighten the locknuts to 167 Nm (17.0 kgf-m, 123 ft. lbs.).

NOTE:
- Use a torque wrench to tighten the locknuts. Do not use an impact wrench.
- Countershaft and secondary shaft locknuts have left-hand threads.

24. Remove the special tool from the mainshaft.





25. Stake each locknut into its shaft using 3.5 mm punch.





26. Set the park lever in P position, then verify that the park pawl (A) engages the park gear (B).
27. If the park pawl does not engage fully, check the distance between the pawl shaft (C) and the park lever roller pin (D).
28. Tighten the lock bolt (E), and bend the lock tab of the lock washer (F) against the lock bolt head.





29. Install the end cover (A) with the two dowel pins, new O-rings, new gasket, harness clamp bracket (B), and connector bracket (C). Tighten the 13 bolts to 12 Nm (1.2 kgf-m, 8.7 ft. lbs.) in a crisscross pattern.





30. Install the 8 x 12 mm ATF feed pipe (A) with its filter side into the transmission housing.
31. Install the new gasket (B) in the mounting groove of the A/T clutch pressure control solenoid valve C body (C) properly, then install them on the transmission housing. Do not pinch the gasket.
32. Install the ATF dipstick guide pipe (D) with the new O-ring (E).
33. Place the new gasket (F) on the transmission housing, then install the 8 x 18 mm ATF feed pipes (G) with their filter side into the transmission housing.
34. Install the new O-rings (H) over the feed pipes, and install the 8 x 40 mm ATF feed pipe (I).
35. Install the A/T clutch pressure control solenoid valves A and B (J) and the harness clamp bracket (K).





36. Place the new ATF passage body gasket (A) on the transmission housing, then install the 8 x 14 mm dowel pin (B) and the 10 x 25.5 mm ATF feed pipe (C) with the new O-ring (D). Install the ATF passage body (E) on the transmission housing, if it was removed.





37. Install the new ATF filter (A) on the transmission housing.
38. Install the filter line bracket (B) on the ATF filter, and loosely install the bolts (C).
39. Install the new O-ring (D) to the filter line (E), then install the filter line on the ATF filter.
40. Secure the end of the filter line on the bracket (F) with the bolt (G).
41. Secure the filter line on the filter line bracket with the bolts (H).
42. Tighten the bolts (C) on the filter line bracket to the specified torque.
43. Install the ATF hose (I) and line bolt (J) with the new sealing washers (K).
44. Connect the hose to the filter line, and secure it with the clip (L).





45. Install the ATF cooler lines (A) with the new sealing washers (B) and the line bolts, then install the harness clamp bracket (C).





46. Set the transmission range switch to the N position.

NOTE: The transmission range switch clicks in the N position.





47. Set the control shaft (A) to the N position by turning it.

NOTE: Be careful not to squeeze the end of the control shaft tips together when turning into position. If the tips are squeezed together it will cause a faulty signal or position due to the play between the control shaft and the switch.

48. Install the transmission range switch cover (C); secure the harness with the bolt on the end cover (D); install the harness clips (E) on the brackets (F).





49. Install the transmission range switch cover (C); secure the harness with the bolt on the end cover (D); install the harness clips (E) on the brackets (F).





50. Connect the 3rd clutch pressure switch connector (A) and A/T wire harness ground terminal (B) on the connector bracket (C), then install the clips (D) on the bracket (E).
51. Install the switch cover (F).
52. Install the ATF temperature sensor (G) with the new O-ring (H), then secure the harness with the bolts. Connect the sensor connector to the A/T wire harness connector, then install it on the connector bracket (C).
53. Install the dipstick.