Part 1

Mainshaft 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, 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 5th gear.

Mainshaft 5th Gear Axial Clearance Inspection
1. Remove the mainshaft transmission housing bearing.





2. Assemble 41 x 68 mm thrust washer (A), 4th/5th clutch (B), 4th gear collar (C), and 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 by 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.

THRUST WASHER, 41 x 68 mm:

7. Select and install a new thrust washer, then recheck.
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, and all gears 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, and the 3rd gear are press-fitted to the countershaft; special tools are needed to remove them and to install them.

Countershaft Reverse Selector Hub and 3rd Gear Removal

Special Tools Required
Bearing separator 07KAF-PS30200





1. Install the special tool on the 4th gear (A). Set a press on the countershaft (B) with putting a spacer (C) between the press and countershaft, and remove the reverse selector hub (D).

NOTE: Some reverse selector hubs are not press-fitted, and can be removed without using the special tool and a press.

2. Remove the needle bearing, set ring, 35 x 47 x 7.8 mm collar, and cotters.





3. Set the press on the countershaft (A) with putting a spacer (B) between the press and countershaft, and remove the 3rd gear (C).
4. Remove the 37 x 41 x 57.8 mm collar, 5th gear, 1st gear, and 2nd gear.

Countershaft 3rd, Gear and Reverse, Selector Hub Installation

Special Tools Required
Driver, 40 mm I.D. 07746-0030100

1. Install the 2nd gear, 1st gear, 5th gear, and 37 x 41 x 57.8 mm collar on the countershaft.





2. Slide the 3rd gear (A) over the countershaft, and press it in place with the special tool and a press.
3. Install the cotters, 35 x 47 x 7.8 mm collar, set ring, needle bearing, and 4th gear.





4. Slide the reverse selector hub (A) over the countershaft, 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 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, idler gear in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the clearance of the 2nd gear and 1st gear.

Secondary Shaft Ball Bearing, Idler Gear Removal and Installation

Special Tools Required
Attachment, 42 mm I.D. 07QAD-P0A0100

Removal





Place a shaft protector (A) on the secondary shaft (B), and set the puller (C) under 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) over the idler gear with the special tool and a press.

Secondary Shaft 2nd Gear 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.

THRUST WASHER, 37 x 58 mm:

4. Select and install a new thrust washer, then recheck.
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. 07QAD-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/3rd clutch (F), and 3rd gear 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.

THRUST WASHER, 40 x 51.5 mm:

7. Select and install a new thrust washer, then recheck.
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.

Idler Gear Shaft Removal and Installation





1. Remove the snap ring (A), cotter retainer (B), and cotter keys (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. 2003-2005-model 1st clutch:
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. 2003-2005-model 2nd clutch:
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).
4. Make a reference mark on 2.0 mm-thick flat-plate (D).





5. 2003-2005-model 3rd clutch:
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 3rd clutch drum (F).
6. Make reference marks on the clutch flat-plates (D).





7. 2003-2004-model 4th clutch:
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).





8. 2003-2004-model 5th clutch:
Remove the clutch end plate (A), clutch discs (8) (3), clutch waved-plates (C) (3), and waved spring (D) from the 5th clutch drum (E).





9. 2005-model 4th clutch:
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).





10. 2005-model 5th clutch:
Remove the clutch end plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 5th clutch drum (E).





11. 2006-2007-model 1st clutch:
Remove the clutch end plate (A), clutch discs (B) (5 clutch waved-plates (C) (4), clutch flat-plate (D) (1), and waved spring (E) from the 1st clutch drum (F).
12. Make reference marks on the clutch waved-plates.





13. 2006-2007-model 2nd clutch:
Remove the clutch end plate (A), clutch discs (B) (6), clutch waved-plates (C) (5), clutch flat-plate (D) (1), and waved spring (E) from the 2nd clutch drum (F).
14. Make reference marks on the clutch waved-plates.





15. 2006-2007-model 3rd clutch:
Remove the clutch end plate (A), clutch discs (B) (6), clutch waved-plates (C) (5), clutch flat-plate (D) (1), and waved spring (E) from the 3rd clutch drum (F).
16. Make reference marks on the clutch waved-plates.





17. 2006-2007-model 4th clutch:
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).





18. 2006-2007-model 5th clutch:
Remove the clutch end plate (A), clutch discs (B) (4), clutch waved-plates (C) (4), and waved spring (D) from the 5th clutch drum (E).





19. Install the special tools.





20. Set the special tool (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches so the special tool works on the clutch return spring (C).





21. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.





22. If either end of the special tool is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.





23. Compress the return spring until the snap ring can be removed.





24. Remove the snap ring with the snap ring pliers.
25. Remove the special tools.





26. Remove the snap ring (A), spring retainer (B), and return spring (C).





27. 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 passage while applying air pressure.





28. 1st, 2nd, and 3rd clutches:
Remove the clutch piston (A), remove the O-ring (B) from the piston, and remove the O-ring (C) from the clutch drum (D).





29. 4th and 5th clutches:
Remove the clutch piston (A), and remove the outer O-ring (B) and inner O-ring (C) from the piston.

Clutch Inspection





1. Inspect the clutch pistons and clutch piston check valves (A).
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.
4. If the spring retainer is worn or damaged, replace it.





5. Check the oil seal (A) on the spring retainer of the 1st, 2nd, and 3rd clutches for wear, damaged, and peeling.
6. If the oil seal is worn, damaged or peeling replace the spring retainer.
7. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
Clutch Discs for All Models
Standard Thickness: 1.94 mm (0.076 inch)

Clutch Plates
Standard Thickness

2003-2004 Models
1st Clutch (waved-plates): 1.6 mm (0.063 inch)
2nd Clutch
Waved-plates, 2.0 mm (0.079 inch)
Flat-plate: 2.0 mm (0.079 inch)
4.0 mm-thick plate: 4.0 mm (0.157 inch)
3rd Clutch
Waved-plates: 1.6 mm (0.063 inch)
Flat-plates: 1.6 mm (0.063 inch)
4th Clutch (waved-plates): 2.3 mm (0.091 inch)
5th Clutch (waved-plates): 2.3 mm (0.091 inch)

2005 Model
1st Clutch (waved-plates): 1.6 mm (0.063 inch)
2nd Clutch
Waved-plates: 2.0 mm (0.079 inch)
Flat-plate: 2.0 mm (0.079 inch)
4.0 mm-thick plate: 4.0 mm (0.157 inch)
3rd Clutch
Waved-plates: 1.6 mm (0.063 inch)
Flat-plates: 1.6 mm (0.063 inch)
4th Clutch (waved-plates): 2.0 mm (0.079 inch)
5th Clutch (waved-plates): 2.0 mm (0.079 inch)

2006-2007 Models
1st Clutch
Waved-plates: 1.6 mm (0.063 inch)
Flat-plates: 1.6 mm (0.063 inch)
2nd Clutch
Waved-plates: 2.0 mm (0.079 inch)
Flat-plate: 2.0 mm (0.079 inch)
3rd Clutch
Waved-plates: 1.6 mm (0.063 inch)
Flat-plates: 1.6 mm (0.063 inch)
4th Clutch (waved-plates): 2.0 mm (0.079 inch)
5th Clutch (waved-plates): 2.0 mm (0.079 inch)

8. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clutch end-plate-to-top-disc clearance.
9. If any plate is worn, damaged, or discolored, replace the damaged plate with a new plate, and inspect the other waved-plates for a phase difference. If the clutch plate is replaced, inspect the clutch end-plate-to-top-disc clearance.
10. 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.

Clutch Waved-plate Phase Difference Inspection





1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (D) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the waved-plate about 60-degrees apart from the bottom while holding the waved-plate by its circumference. The dial indicator should be at the top (E) of a phase difference. Do not rotate the waved-plate while holding its surface, always rotate it with holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top.
Standard Phase Difference
1st clutch: 0.15 - 0.25 mm (0.006 - 0.010 inch)
2nd clutch: 0.1 - 0.2 mm (0.004 - 0.008 inch)
3rd clutch: 0.1 - 0.2 mm (0.004 - 0.008 inch)
4th clutch: 0.1 - 0.2 mm (0.004 - 0.008 inch)
5th clutch: 0.1 - 0.2 mm (0.004 - 0.008 inch)
5. Rotate the waved-plate about 60-degrees. The dial indicator should be at the bottom of a phase difference (F and H), and zero the dial indicator.
6. Measure the phase difference at the other two tops (G and I) of the waved-plate by following steps 3 thru 5.
7. If the two values of the three measurements are within the standard, the waved-plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.