Part 1
Mainshaft Bearing and Oil Seal ReplacementSpecial Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 62 x 68 mm 07746-0010500
^ Attachment, 72 x 75 mm 07746-0010600
1. Remove the mainshaft bearing and oil seal with the adjustable bearing puller and a commercially available 3/8 "-16 slide hammer (A).
2. Install the new mainshaft bearing until it bottoms in the housing with the driver and attachment (62 x 68 mm).
3. Install the new oil seal flush to the housing with the driver and attachment (72 x 75 mm).
Countershaft Bearing Replacement
Special Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 78 x 80 mm 07NAD-PX40100
1. Remove the countershaft bearing from the torque converter housing with the adjustable bearing puller and a commercially available 3/8 "-16 slide hammer (A).
2. Install the ATF guide plate (A) into the housing, then install the new bearing (B) in the direction shown.
3. Install the bearing (A) in the housing with the driver and attachment (78 x 80 mm); install bearing outer race notch-cut (B) to a depth (C) of 0-0.03 mm (0-0.001 in.) below the housing surface (D).
Secondary Shaft Bearing Replacement
Special Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Bearing remover shaft set, 30 mm 07936-8890300
^ Bearing remover shaft handle 07936-3710100
^ Sliding hammer weight 07741-0010201
^ Driver 07749-0010000
^ Attachment, 37 x 40 mm 07746-0010200
^ Attachment, 62 x 68 mm 07746-0010500
1. Remove the bolt, then remove the lock washer (A) and bearing set plate (B).
2. Remove the secondary shaft bearing from the torque converter housing with the adjustable bearing puller (25-40 mm), and a commercially available 3/8 "-16 slide hammer (A).
3. Remove the ATF guide collar from the torque converter housing.
4. Remove the 29 x 39 x 9.5 mm secondary shaft bearing from the torque converter housing with the bearing remover shaft set (30 mm), bearing remover shaft handle, and sliding hammer weight.
5. Install the 29 x 39 x 9.5 mm bearing into the torque converter housing with the driver and attachment (37 x 40 mm).
6. Install the new O-rings (A) on the ATF guide collar (B), then install the guide collar in the torque converter housing
7. Install the bearing in the direction shown in the housing with the driver and attachment (62 x 68 mm).
8. Check that the bearing groove aligns with the set plate mounting surface, then install the set plate (A) by aligning it with the bearing groove.
9. Install the new lock washer (B) and bolt, then bend the lock tab of the lock washer against the bolt head.
Intermediary Shaft Bearing Replacement
Special Tools Required
^ Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
^ Driver 07749-0010000
^ Attachment, 52 x 55 mm 07746-0010400
1. Remove the intermediary shaft bearing from the torque converter housing with the adjustable bearing puller (25-40 mm), and a commercially available 3/8 "-16 slide hammer (A).
2. Install the ATF guide plate (A), then install the new bearing (B) in the housing.
3. Drive the bearing into the housing with the driver and attachment (52 x 55 mm).
Park Lever Shaft Bearing Replacement
Special Tools Required
^ Bearing remover shaft set, 12 mm 07936-1660101
^ Sliding hammer weight 07741-0010201
^ Driver 07749-0010000
^ Attachment, 22 x 24 mm 07746-0010800
1. Remove the park lever shaft bearing from the torque converter housing with the bearing remover shaft set (12 mm), and sliding hammer weight.
2. Install the new bearing until it bottoms in the housing with the driver and attachment (22 x 24 mm).
Mainshaft Disassembly, Inspection, and Reassembly
1. Remove the thrust needle bearing (A), the mainshaft 5th gear (B), the needle bearing (C), the thrust needle bearing (D), the mainshaft 5th gear collar (E), the 4th/5th clutch (F), and the O-rings (G) from the mainshaft (H).
Mainshaft:
2. Inspect the condition of the sealing rings (I). If the sealing rings are worn, distorted, or damaged, remove the set ring (J) and the needles bearing (K), and replace the sealing rings with new ones.
3. Inspect the thrust needle bearing and needle bearing for wear and rough movement.
4. Inspect the splines for excessive wear and damage.
5. Inspect the 4th gear for wear and damage, and inspect the 4th gear bearing for wear and rough rotation.
6. Replace the mainshaft 4th gear (L) if the 4th gear is worn or damaged, or the bearing is worn or damaged.
7. Check the shaft bearing surfaces for scoring and excessive wear.
8. Lubricate all parts with ATF during reassembly.
9. Wrap the shaft splines with tape to prevent O-ring damage, install the new O-rings on the mainshaft, then remove the tape.
10. Install the 4th/5th clutch.
11. Install the mainshaft 5th gear collar, the thrust needle bearing, the needle bearing, the mainshaft 5th gear, and the thrust needle bearing.
Mainshaft 4th Gear Replacement
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Remove the mainshaft 4th gear (A) with a press. Place a shaft protector (B) between the press and mainshaft (C) to prevent damaging the mainshaft.
2. Slide the new mainshaft 4th gear (A) over the mainshaft (B), then press it into place with the driver (40 mm I.D.), and the press.
Countershaft Disassembly
Exploded View
Countershaft:
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Cut the lock tab (A) of the countershaft locknut (B) using a chisel (C).
NOTE: Keep all of the chiseled particles out of the countershaft.
2. Hold the countershaft with a wrench and a vise securely, loosen the locknut, and remove it. The locknut has left-hand threads.
3. Place the countershaft 5th gear (A) on press bases (B), and place a shaft protector (C) between the countershaft (D) and a press to prevent damaging the countershaft.
4. Press the countershaft out of the press-fitted bearing (E) and the press-fitted reverse selector hub, and remove the countershaft while holding the underside of the countershaft. The countershaft falls down when pressing the countershaft out of the press-fitted reverse selector hub. Some reverse selector hubs are not press-fitted, and the countershaft falls down when pressing the countershaft out of press-fitted bearing.
5. Remove the remaining parts from the countershaft.
6. Inspect the bearing for galling and rough movement.
7. Check the shaft bearing surfaces for scoring and excessive wear, and check the shaft splines for excessive wear and damage.
NOTE: If the countershaft is worn or damaged, replace the countershaft with the same letter (A, B, or C) for identification as the identifying letter on the final driven gear.
8. Check the idler gear axial clearance and the 4th gear axial clearance.
Countershaft Idler Gear and 4th Gear Axial Clearance Inspection
1. Install the 40.5 mm cotters (A), 2nd gear (B), thrust needle bearing (C), needle bearing (D), idler gear (E), thrust needle bearing (F), 61 mm washer (G), 1st gear (H), 4th gear (I), 50.8 mm collar (J), 50.8 mm washer (K), 42.2 mm cotters (L), cotter retainer (M), and snap ring (N) on the countershaft (0). Install the 40.5 mm cotters, idler gear, 1st gear, and 4th gear in the direction shown.
2. Insert a feeler gauge blade (A) as thick as possible between the 50.8 mm collar (B) and 50.8 mm washer (C).
3. Set the dial indicator (A) on the idler gear (B).
4. Measure the idler gear axial clearance in at least three places while moving the idler gear. Use the average as the actual clearance.
Standard: 0.005-0.040 mm (0.0002-0.0016 in.)
5. If the measurement is out of standard, remove the 61 mm washer and measure its thickness.
6. Select and install a new washer, then recheck the clearance.
7. Measure the clearance between the 50.8 mm collar (A) and the 50.8 mm washer (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.
Standard: 0.005-0.040 mm (0.0002-0.0016 in.)
8. If the measurement is out of standard, remove the 50.8 mm washer and measure its thickness.
9. Select and install a new washer, then recheck the clearance.
Countershaft Reassembly
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Verify that the identifying letter (A, B, or C) on the top of the countershaft (D) matches the letter on the final driven gear. The identifying letters should be same.
2. Install the 40.5 mm cotters (E), 2nd gear (F), thrust needle bearing (G), needle bearing (H), idler gear (I), thrust needle bearing (J), 61 mm washer (K), 1st gear (L), 4th gear (M), 50.8 mm collar (N), 50.8 mm washer (0), 42.2 mm cotters (P), cotter retainer (Q), and snap ring (R) on the countershaft. Install the 40.5 mm cotters, idler gear, 1st gear, and 4th gear in the direction shown.
3. Install the 35 x 47 x 6 mm thrust washer (S) in the direction shown, then install the needle bearing (T) and the 5th gear (U).
4. Slide the reverse selector hub (A) over the countershaft (B), then press it into place with the driver (40 mm I.D.) and a press.
NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the driver (40 mm I.D.), and a press.
5. Install the reverse selector, the reverse gear collar, the needle bearing, and the reverse gear over the reverse selector hub.
6. Install the ball bearing (A) over the countershaft, then press it into place with the driver (40 mm I.D.), and the press.
7. Install the conical spring washer (A) in the direction shown, and install the new locknut (B).
8. Hold the countershaft securely with a wrench and a vise, and tighten the locknut to 167 N.m (17.0 kgf.m, 123 lbf. ft).
NOTE:
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ The locknut has left-hand threads.
9. Stake the locknut into its shaft in depth (A) of 0.7-1.3 mm (0.03-0.05 in.) using a 3.5 mm punch (B).
Secondary Shaft Disassembly
Exploded View
Secondary Shaft:
Special Tools Required
Wrench, 40 x 42 mm 07XAA-002010A
NOTE: Refer to the Exploded View as needed during the following procedure.
1. Cut the lock tab (A) of the secondary shaft locknut (B) using a chisel (C).
NOTE: Keep all of the chiseled particles out of the secondary shaft.
2. Place a V-block (A) on the back of a vise (B), and clamp the wrench (40 x 42 mm), in the vise jaws (C).
3. Place the secondary shaft on the block, and attach the 1st clutch guide (D) to the wrench (40 x 42 mm). Loosen the locknut, and remove it. Remove any burrs from the splines on the shaft and the spline, the washer.
4. Place the idler gear (A) on press bases (B), and place a shaft protector (C) between the secondary shaft (D) and a press to prevent damaging the secondary shaft.
5. Press the secondary shaft out of the press-fitted bearing (E), and remove the secondary shaft while holding the underside of the secondary shaft. The secondary shaft falls down when pressing the secondary shaft out of the press-fitted bearing.
6. Remove the 1st/1st-hold clutch, 52 mm washer, thrust needle bearing, 1st gear assembly, needle bearing, 1st gear collar, thrust needle bearing, and idler gear.
7. Remove the 32 mm snap ring, and remove the 2nd clutch, splined washer, thrust needle bearing, needle bearing, 2nd gear/park gear, and thrust needle bearing.
8. Inspect the bearings for galling and rough movement.
NOTE: The needle bearing (A) on the 1st gear collar should have only two cavities with no rollers (B); this is function in its normal.
9. Check the shaft bearing surfaces for scoring and excessive wear, and check the shaft splines for excessive wear and damage.
10. Check the 1st gear axial clearance, 1st gear one-way clutch, and secondary shaft installation height.
Secondary Shaft 1st Gear Axial Clearance Inspection
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
1. Install the idler gear (A), thrust needle bearing (B), 1st gear collar (C), needle bearing (D), 1st gear assembly (E), thrust needle bearing (F), 52 mm washer (G), and 1st/1st-hold clutch (H) on the secondary shaft (I). Install the idler gear and 52 mm washer in the direction shown. Do not install the O-rings during inspection.
2. Install the ball bearing (A) over the 1st/1st hold clutch guide with the driver (40 mm I.D.). attachment (30 mm I.D.). and a press.
3. Install the splined washer with the marked side up over the ball bearing in the same manner as installing the ball bearing with the driver (40 mm I.D.), attachment (30 mm I.D.), and the press.
4. Install the old locknut and tighten it to 29 N.m (3.0 kgf.m, 22 lbf.ft).
5. Set the dial indicator (A) on the 1st clutch hub (B).
6. Measure the 1st gear axial clearance in at least three places while moving the 1st gear. Use the average as the actual clearance. Standard: 0.100-0.130 mm (0.004-0.05 in.)
7. If the clearance is out of standard, remove the washer and measure its height difference.
8. Select and install a new washer, then recheck the clearance. 1st Gear One-way Clutch Inspection
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 locks 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.
3. Also check the 1st gear and the 1st-hold clutch hub for wear and damage. If the 1st gear and 1st-hold clutch hub are worn or damaged, replace the damaged part, refer to 1st Clutch Hub Replacement.
1st Clutch Hub Replacement
Special Tools Required
^ Driver 07749-0010000
^ Driver attachment 07947-6340500
^ Attachment, 78 x 80 mm 07GAD-SD40101
1. Remove the 1st-hold clutch hub (A) from the 1st gear (B) with the driver, driver attachment, and a press.
2. Remove the 1st clutch hub (C) from the 1st gear.
3. Install the new 1st clutch hub (A) over the 1st gear (B), and install the 1st-hold clutch hub (C) in the 1st gear.
NOTE: If the 1st gear and the 1st-hold clutch hub are replaced, use the 1st gear and the 1st-hold clutch hub with the same identifying letters (A or B).
4. Install the 1st-hold clutch hub (A) in the 1st gear (B) with the driver, attachment (78 x 80 mm), and the press.
Secondary Shaft Reassembly
Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300
^ Wrench, 40 x 42 mm 07XAA-002010A
1. Install the thrust needle bearing (A), the needle bearings (B), the 2nd gear/park gear (C), the thrust needle bearing (D), and the splined washer (E) in the direction shown on the secondary shaft (F).
2. Wrap the shaft splines with tape, and install new O-rings (G) in the 2nd clutch O-ring grooves, then remove the tape.
NOTE: To prevent damage to the O-rings, be sure to install the O-rings after installing the splined washer.
3. Install the 2nd clutch (H) on the secondary shaft, and secure the 2nd clutch with the snap ring (I).
4. Install the idler gear (A) in the direction shown, the thrust needle bearing (B), the 1st gear collar (C), the needle bearing (D), the 1st gear assembly (E), the thrust needle bearing (F), and the 52 mm washer (G) in the direction shown on the secondary shaft (H).
NOTE: It is normal for the needle bearing (D) to have two cavities (I) without rollers.
5. Wrap the shaft splines with tape, and install new O-rings (J) in the 1st/1st-hold clutch O-ring grooves, then remove the tape.
NOTE: To prevent damage to the O-rings, be sure to install the O-rings after installing the 1st gear collar and the 52 mm washer.
6. Install the 1st/1st-hold clutch (K).
7. Install the ball bearing (A) over the 1st/1st-hold clutch guide (B) with the driver (40 mm I.D.), attachment (30 mm I.D.), and a press.
8. Install the new splined washer (A) with the marked side (B) up over the ball bearing with the driver (40 mm I.D.), attachment (30 mm I.D.), and the press.
9. Install the new locknut (A).
10. Place a V-block (A) on a vise (B), and put the secondary shaft (C) on the V-block and vise.
11. Attach the wrench (40 x 42 mm), onto the top of the 1st clutch guide, and secure the wrench (40 x 42 mm), with the vise to hold the secondary shaft. Tighten the locknut to 178 N.m (18.2 kgf.m, 132 lbf.ft) with the torque wrench (D).
NOTE:
^ Use a torque wrench to tighten the locknut. Do not use an impact wrench.
^ The locknut has left-hand threads.
12. Stake the locknut into the shaft to a depth (A) of 0.7-1.3 mm (0.03-0.05 in.) using a 3.5 mm punch (B).
