2. Transmission Housing Disassemble & Service
Housing and Shaft Assembly Removal
Exploded View - 4WD
Exploded View- 2WD
Special Tools Required
Housing puller 07HAC-PK40102
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Remove the ATF feed pipe from the idler gear shaft, and the ATF lubrication pipe from the transmission housing.
2. Remove the shift solenoid valve cover (A), dowel pins (B), and gasket (C).
3. Remove the bolt (A) securing the solenoid harness connector (B), and remove the connector.
4. Disconnect the connectors from the shift solenoid valves.
5. Remove the mainshaft and countershaft speed sensors.
6. Remove the transmission housing mounting bolts, hanger, and harness clamp brackets.
7. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C) by turning the selector control shaft.
NOTE: Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together it could cause a faulty signal or position due to the play between the selector control shaft and the switch.
8. While expanding the snap ring of the secondary shaft bearing using the snap ring pliers, lift the transmission housing. Release the snap ring pliers, and remove the transmission housing.
9. Remove the countershaft reverse gear and needle bearing.
10. Remove the lock bolt securing the shift fork, then remove the shift fork with the reverse selector together.
11. Remove the selector control lever from the selector control shaft.
12. Unhook the detent spring (A) from the detent arm (B).
13. Remove the selector control shaft (A).
14. Remove the mainshaft subassembly (A), countershaft subassembly (B), and secondary shaft subassembly (C) together.
15. Remove the differential assembly.
16. 2005 model: Remove the baffle plate.
17. 4WD model: Remove the transfer assembly.
Bearing Removal
Special Tools Required
^ Attachment, 78 x 90 mm 07GAD-SD40101
^ Driver 07749-0010000
^ Attachment, 42 x 47 mm 07746-0010300
1. Remove the idler gear shaft when removing the mainshaft bearing and idler gear shaft bearing.
NOTE: If you are only removing the countershaft bearing, idler gear shaft removal is not needed.
2. To remove the mainshaft bearing (A) and countershaft bearing (B) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out.
NOTE: Do not remove the snap ring unless it's necessary to clean the grooves in the housing.
3. Expand the snap ring of the idler gear shaft bearing with the snap ring pliers, then push the bearing out.
Bearing Installation
Special Tools Required
^ Attachment, 78 x 90 mm 07GAD-SD40101
^ Driver 07749-0010000
^ Attachment, 42 x 47 mm 07746-0010300
1. Install the bearings in the direction shown.
2. Expand each snap ring with the snap ring pliers, and install the mainshaft bearing (A) and countershaft bearing (B) part-way into the housing.
3. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
4. Expand the snap ring of the idler gear shaft (A) with the snap ring pliers, and install the bearing partway into the housing.
5. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
6. After installing the bearings verify that the snap rings (A) are seated in the bearing and housing grooves, and that the ring end gaps (B) are correct.
7. Install the idler shaft.
Reverse Idler Gear Removal and Installation
Removal
1. Remove the bolt (A) securing the reverse idler gear shaft holder.
2. Install a 5 x 0.8 mm bolt (B) in the reverse idler gear shaft, and pull it to remove the reverse idler gear shaft (C) and gear shaft holder (D) together.
3. Remove the reverse idler gear.
Installation
1. Install the reverse idler gear in the transmission housing.
2. Coat the reverse idler gear shaft (A), needle bearing (R) and new O-rings (C) with lithium grease lightly.
3. Assemble the 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 cut out (E) of the shaft with the D-shaped area (F) of the holder.
4. Install the reverse idler gear shaft/holder assembly on the transmission housing.
Shaft Assembly and Housing Installation
Exploded View
NOTE: Refer to the Exploded View as needed during the following procedure. The Exploded View shows the 4WD transmission model; the 2WD transmission is similar.
1. Install the differential assembly in the torque converter housing.
2. 2005 model: Install the baffle plate on the servo body.
3. Assemble the mainshaft, countershaft, and secondary shaft.
4. Join the mainshaft subassembly (A), countershaft subassembly (B), and secondary shaft subassembly (C) together, and install them in the torque converter housing.
5. If the detent arm was removed, install the detent arm (A) with arm collar (B) on the servo body (C), and install the new lock washer (D) by aligning its cutout (E) with the projection (F) of the servo body. Install and tighten the bolt, then bend the lock tab of the lock washer against the bolt head.
6. Install the selector control shaft (A) in the torque converter housing aligning the manual valve lever pin (B) on the selector control shaft with the guide of the manual valve (C). Pull the manual valve gently when aligning the manual valve with the selector control shaft.
7. Hook the detent arm spring (A) to the detent arm (B).
8. Turn the shift fork shaft (A) so the large chamfered hole (B) is facing the fork bolt hole (C) of the shift fork (D).
9. Install the shift fork and reverse selector together on the shift fork shaft and 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.
10. Install the needle bearing and countershaft reverse gear on the countershaft.
11. Install the reverse idler gear in the transmission housing.
12. Install the idler gear shaft, if it was removed.
13. Install the three dowel pins and a new gasket on the torque converter housing.
14. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C) by turning the selector control shaft.
NOTE: Do not squeeze the end (D) of the selector control shaft tips together when turning the shaft. If the tips are squeezed together it could cause a faulty signal or position due to the play between the selector control shaft and the switch.
15. Place the transmission housing on the torque converter housing. Do not install the mainshaft and countershaft speed sensors before installing the transmission housing on the torque converter housing.
16. While expanding the snap ring of the secondary shaft bearing using snap ring pliers, install the transmission housing onto the bearing part-way. Then release the pliers, and push down on the housing until it bottoms and the snap ring snaps into place in the transmission housing snap-ring groove.
17. Verify that the secondary shaft bearing snap ring (A) is seated in the bearing and housing groove, and that the ring end gap (B) is correct.
18. Install the transmission housing mounting bolts along with the transmission hanger (A) and harness clamp brackets (B), and tighten the bolts in two or three steps in a crisscross pattern.
19. Install the input shaft (mainshaft) speed sensor (A) and output shaft (countershaft) speed sensor (B) with new O-rings (C).
20. Install the shift solenoid harness connector (F) in the transmission housing with the new O-ring (G).
21. Connect the connector (BLU, WHT and WHT wires) to the shift solenoid valve A.
22. Connect the connectors to the respective solenoid valves:
^ ORN wire to shift solenoid valve B.
^ GRN wire to shift solenoid valve C.
^ RED wire to shift solenoid valve E.
23. Install the shift solenoid valve cover (A) with the two dowel pins (B) and the new gasket (C), and tighten the bolts (eight). Install the one bolt with the bracket for the ATF cooler line in the bolt hole (D).