Part 1
Shafts and ClutchesMainshaft Disassembly, Inspection, and Reassembly
1. Lubricate all parts with [1][2]ATF during assembly.
2. Check the clearance of the 4th/5th clutch assembly.
3. Inspect the thrust needle bearing and the needle bearing for scoring and rough movement.
4. Inspect the splines for excessive wear and damage.
5. Check shaft bearing surfaces for scoring and excessive wear.
6. Before installing the O-rings, wrap the shaft splines with tape to prevent C-ring damage.
7. Install the 41 x 73 mm thrust shim and conical spring washer in the direction shown.
8. Inspect the condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them.
4th/5th Clutch Clearance Inspection
1. Remove the O-rings from the mainshaft.
2. Assemble the 41 x 73 mm thrust shim (A), 4th/5th clutch assembly (B), and 5th gear collar (C) on the mainshaft (D).
3. Hold the 5th gear collar (C) against the clutch assembly (B), then measure the clearance between the clutch guide (E) and the 5th gear collar with a feeler gauge (F) in at least three places. Use the average as the actual clearance.
4. If the clearance is out of standard, remove the thrust shim and measure its thickness.
THRUST SHIM, 41 x 73 mm:
5. Select and install a new shim, then recheck.
6. After replacing the thrust shim, make sure the clearance is within standard.
Mainshaft 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 [1][2]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 tw1sted.
^ The chamfered ends of the rings are properly joined.
Countershaft Disassembly, Inspection, and Reassembly
1. Remove the locknut, and take off components down to the reverse selector hub.
2. Remove the reverse selector hub, 4th gear, and 1st gear.
3. Check the bearing on the 3rd clutch for wear and rough movement. If the bearing is worn or damaged, replace it.
4. Inspect the thrust needle bearing and the needle bearing for scoring and rough movement.
5. Check the splines for excessive wear and damage.
6. Check the shaft bearing surfaces for scoring and excessive wear.
7. Lubricate all parts with [1][2]ATF, and reassemble the shaft and gears.
8. Install the distance collars, reverse selector hub, reverse selector, splined washer, and conical spring washer in the direction shown.
Countershaft Reverse Selector Hub and 4th Gear Removal
1. Remove the reverse selector hub (A) and the 5th gear (B) from the countershaft with a press. Place a shaft protector (C) 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. Remove the needle bearing, snap ring, 35 x 47 x 7.8 mm distance collar, 31 mm cotters, 35 x 47 x 45.5 mm distance collar, and 31 mm cotters from the countershaft.
3. Remove the 1st gear (A) and 4th gear (B) from the countershaft with a press. Place a shaft protector (C) between the countershaft and press to prevent damaging the countershaft.
Countershaft 4th Gear and Reverse Selector Hub Installation
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Apply [1][2]ATF to the parts.
2. Install the 1st gear on the countershaft by hand.
3. Align the shaft splines with those on 4th gear, then press the countershaft (A) into the 4th gear with a press. Place a shaft protector (B) between the countershaft and press to prevent damaging the countershaft.
4. Stop pressing the countershaft when the 4th gear contacts the 1st gear (C).
5. Install the 31 mm cotters, 35 x 47 x 45.6 mm distance collar, 31 mm cotters, 35 x 47 x 7.8 mm distance collar, snap ring, needle bearing, and 5th gear (A) on the countershaft.
6. Slide the reverse selector hub (B) over the countershaft (C), then press it into place with the special tool and a press.
NOTE: Some reverse selector hubs are not press fitted, and can be installed without using the special tool and a press.
3rd Clutch Ball Bearing Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 62 x 68 mm 07746-0010500
NOTE: Check the bearing for wear and rough movement. If the bearing is OK, removal is not necessary.
1. Remove the ball bearing (A) from the 3rd clutch with a commercially available bearing puller (B), bearing separator (C), and stepper adapter (D).
2. Install the new bearing on the 3rd clutch with the special tools and a press.
Secondary Shaft Disassembly, Inspection, and Reassembly
1. Remove the locknut, and disassemble the shaft and gears.
2. Inspect the thrust needle bearing and needle bearing for wear and rough movement,
3. Check the clearance of the secondary shaft assembly.
4. Check the splines for excessive wear and damage.
5. Check the shaft bearing surfaces for scoring and excessive wear.
6. Check the idler gear bearing for wear and rough movement. If the bearing is worn or damaged, replace it.
7. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
8. Lubricate all parts with [1][2]ATF during reassembly.
9. Install the splined washer and conical spring washer in the direction shown.
Secondary Shaft Clearance Inspection
1. Remove the O-rings from the secondary shaft.
2. Assemble the thrust needle bearing (A), 1st gear assembly (B), needle bearings (C), thrust needle bearing (D), 38 x 56.5 mm splined washer (E), 32 mm cotters (F), cotter retainer (G), and snap ring (H) on the secondary shaft (I).
3. Measure the clearance between the 38 x 56.5 mm splined washer (E) and cotters (F) with a feeler gauge (J) in at least three places. Use the average as the actual clearance.
4. If the measurement is out of standard, remove the splined washer, and measure its thickness.
5. Select and install a new splined washer, then recheck the clearance.
SPLINED WASHER, 38 x 56.5 mm 2003-2005 Models:
6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft.
7. Assemble the 1st/1st-hold/2nd clutch assembly (A), 37 x 55 mm thrust washer (B), thrust needle bearing (C) needle bearings (D), 2nd gear (E), thrust needle bearing (F), and 27 x 47 x 5 mm thrust washer (removed from mainshaft) (G) on the secondary shaft sub-assembly (H).
8. Set the dial indicator (I) on the 2nd gear (E).
9. Hold the 27 x 47 x 5 mm thrust washer (G) against the clutch assembly (A), and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear (E). Use the average as the actual clearance.
10. If the measurement is out of standard, remove the 37 x 55 mm thrust washer and measure its thickness.
11. Select and install a new thrust washer, then recheck the clearance.
THRUST SHIM, 37 x 55 mm:
12. Disassemble the shaft and gears.
13. Reinstall the 27 x 47 x 5 mm thrust washer on the mainshaft.
Secondary Shaft Idler Gear Bearing Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 78 x 90 mm 07GAD-SD40101
1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, go to step 2.
2. Place the secondary shaft idler gear in a vise with soft jaws.
3. Remove the bearing (A) from the secondary shaft idler gear (B) with a commercially available bearing puller (C).
4. Install the bearing on the secondary shaft idler gear with the special tools and a press.
1st Gear One-way Clutch Inspection
1. Hold the 1st-hold clutch hub (A), and turn the 1st gear (B) in the direction shown to be sure it turns freely. Also make sure the 1st gear does not turn in the opposite direction.
2. If any problem occurs on the 1st gear one-way clutch, replace the 1st clutch hub (C). The 1st gear one-way clutch is not available separately from the 1st clutch hub.
1st Clutch Hub Replacement
Special Tools Required
^ Driver 07749-0010000
^ Driver attachment 07947-6340500
^ Attachment, 78 x 90 mm 07GAD-SD40101
1. Remove the 1st-hold clutch hub (A) from the 1st gear (B) with the special tools and a press.
2. Remove the 1st clutch hub (C) from the 1st gear, then install the new 1st clutch hub in the 1st gear.
3. Install the 1st-hold clutch hub (A) in the 1st gear (B) with the special tools and a press.
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 (A), then remove the clutch end plate, the clutch discs, and the plates with a screwdriver (B).
2. Make reference marks on the 2nd clutch waved plates on the '06-07 models.
3. Remove the waved spring from the 3rd clutch (2003 model) and 4th clutch (2003-2004 models).
4. Remove the disc spring from the 1st clutch, 5th clutch, 3rd clutch (2004-2007 models), and 4th clutch (2005-2007 models).
5. Install the special tools on the clutch assembly.
6. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 4th, and 5th clutches.
7. Set the special tool (A) on the spring retainer (B) of the 2nd and 3rd clutches so the special tool works on the clutch return spring (C).
8. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.
9. Compress the spring until the snap ring can be removed.
10. Remove the snap ring (A). Then remove the special tools (B), spring retainer (C), and return spring.
11. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.
Clutch Inspection
1st/1st-hold/2nd Clutch (2003-2005 Models)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or stuck damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored; replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch-end-plate.
^ If the 1st-hold clutch plate B is worn, damaged, or discoloration, inspect the 1st-hold clutch plate B-to-top-disc clearance, then replace plate B.
1st/1st-hold/2nd Clutch (2006-2007 Models)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose, stuck, or damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration. Inspect the 2nd clutch waved-plate phase difference on the 2006-2007 models.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch-end-plate.
^ If the 1st-hold clutch plate B is worn, damaged, or discolored, inspect the 1st-hold clutch plate B-to-top-disc clearance, then replace plate B.
3rd Clutch (2003 Model)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or stuck damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration,
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.
3rd Clutch (2004-2007 Models)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose, stuck, or damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.
4th/5th Clutch (2003-2004 Models)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or stuck damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.
4th/5th Clutch (2005 Model)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or stuck damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.
4th/5th Clutch (2006-2007 Model)
1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose, stuck, or damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
^ If the clutch discs are worn or damaged, replace the discs as a set.
^ If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
^ If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.