Part 1
Shafts and ClutchesMainshaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check 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 and 41 x 68 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Check the clearance of the 3rd gear.
Mainshaft 3rd Gear Axial Clearance Inspection
1. Remove the mainshaft transmission housing bearing.
2. Assemble the 41 x 68 mm thrust washer (A), 3rd/4th clutch (B), 4th gear collar (C), and the transmission housing bearing (D) on the mainshaft (E). Do not install the O-rings during inspection.
3. Install the idler gear (F) on the mainshaft with a press, then install the conical spring washer (G) and locknut (H).
4. Tighten the locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.).
5. Measure the clearance between the mainshaft flange (A) and 41 x 68 mm thrust washer (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.
6. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness.
7. Select and install a new thrust washer, then recheck.
THRUST WASHER, 41 x 68 mm
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.
10. 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.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, reverse selector, 35 x 47 x 7.8 mm collar, 3rd gear, 1st gear, and 2nd gear in the direction shown.
6. Replace the locknut and 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; special tools are needed to remove them and to install them.
Countershaft Reverse Selector Hub Removal
1. Remove the reverse selector hub (A) and the 4th 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, set ring, 35 x 47 x 7.8 mm collar, 31 mm cotters, and 37 x 41 x 82.8 mm collar from the countershaft.
3. Remove 1st, 3rd, and 2nd gears from the countershaft by hand.
Countershaft Reverse Selector Hub Installation
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
1. Apply ATF to the parts.
2. Install 2nd, 1st, and 3rd gears on the countershaft by hand.
3. Install the 37 x 41 x 82.8 mm collar, 31 mm cotters, 35 x 47 x 7.8 mm collar, set ring needle bearing, and 4th gear on the countershaft.
4. Slide the reverse selector hub (A) over the countershaft (B), then press it in 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.
Secondary Shaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surfaces 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 and idler gear in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission. The secondary shaft locknut has left-hand threads.
8. Check the clearance of 2nd and 1st gears.
Secondary Shaft Ball Bearing, Idler, Gear Removal and Installation
Special Tools Required
^ Attachment, 42 mm I.D. 07OAD-P0A0100
Removal
Place a shaft protector (A) on the secondary shaft (B), place the puller (C) on the idler gear (D), then remove the idler gear and ball bearing (E).
Installation
Install the idler gear (A) on the secondary shaft (B) and install the ball bearing (C) on the shaft with-the special tool and a press.
Secondary Shaft 2nd Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), needle bearing (B), 2nd gear (C), thrust needle bearing (D), 37 x 58 mm thrust washer (E), and 2nd 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 2nd clutch guide (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 37 x 58 mm thrust washer and measure its thickness.
4. Select and install a new thrust washer, then recheck.
THRUST WASHER, 37 x 58 mm
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the shaft and gears.
Secondary Shaft 1st Gear Axial Clearance Inspection
Special Tools Required
^ Attachment, 42 mm I.D. 07GAD-P0A0100
1. Install the thrust needle bearing (A), needle bearing (B), 1st gear (C), thrust needle bearing (D), 40 x 51.5 mm thrust washer (E), 1st clutch (F), and 27 x 45 x 44 mm collar (G) on the secondary shaft (H).
2. Install the idler gear (I), then install the ball bearing (J) on the idler gear with the special tool and a press.
3. Install the conical spring washer (K) and locknut (L), then tighten the locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.).
4. Turn the secondary shaft assembly upside down, and set the dial indicator (A) on the 1st gear (B).
5. Hold the secondary shaft, and measure the 1st gear axial clearance in at least three places while moving the 1st gear (A). Use the average as the actual clearance.
6. If the clearance is out of standard, remove the 40 x 51.5 mm thrust washer and measure its thickness.
7. Select and install a new thrust washer, then recheck.
THRUST WASHER, 40 x 515 mm
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the he shaft and gears.
Idler Gear Shaft Removal and Installation
1. Remove the snap ring (A), cotter retainer (B), and cotters (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap rings and cotter retainer for wear and damage. Replace them if they are worn, distorted, or damaged.
4. Install the idler gear and shaft in the reverse order of removal.
Idler Gear/Idler Gear Shaft Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 32 x 35 mm 07746-0010100
1. Remove the snap ring from the idler gear/idler shaft assembly.
2. Remove the idler gear shaft (A) from the idler gear (B) with the special tools and a press.
3. Replace the idler gear or idler gear shaft, and attach the idler gear shaft to the idler gear.
4. Install the idler gear shaft (A) in the idler gear (B) with the special tools and a press.
5. Install the snap ring.
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), clutch discs (B) (5), clutch waved-plates (C) (5), and waved spring (D) from the 1st clutch drum (E).
3. 2003-2004 models: Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (3), clutch flat-plates (D) (2), and waved spring (E) from the 2nd clutch drum (F).
4. 2003-2004 models: Make reference marks on the clutch flat-plates (D).
5. 2005-2006 models: Remove the clutch end-plate (A), clutch discs (B) (5), clutch waved-plates (C) (3), 2.0 mm-thick flat-plate (D), 4.0 mm-thick plate (E), and waved spring (F) from the 2nd clutch drum (G).
6. 2005-2006 models: Make reference mark on 2.0 mm-thick flat-plate (D).
7. 2003-2004 models: Remove the clutch end-plate (A), clutch discs (B) (3), clutch waved-plates (C) (3), and waved spring (D) from the 3rd clutch drum (E).
8. 2003-2004 models: Remove the clutch end-plate (A), clutch discs (B) (3), clutch waved-plates (C) (3), and waved spring (D) from the 4th clutch drum (E).
9. 2005-2006 models: Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 3rd clutch drum (E).
10. 2005-2006 models: Remove the clutch end-plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 4th clutch drum (E).
11. Install the special tools.
12. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.
13. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool Works on the clutch return spring (C).
14. 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.
15. Compress the return spring until the snap ring can be removed.
16. Remove the snap ring with snap ring pliers.
17. Remove the special tools.
18. Remove the snap ring (A), spring retainer (B), and return spring (C).
19. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a fingertip on the other passage while applying air pressure.
20. Remove the piston, then remove the O-rings from the 3rd and 4th clutch pistons.
21. Remove the piston, then remove the O-ring from the 1st and 2nd clutch drum, and remove the O-ring from each clutch piston.
