Part One

A/T Clutch Clearance Inspection

























Installation

NOTE:
* Apply a light coat of clean ATF on all moving parts before installation.
* The illustration shows AWD/4WD transmission.

1. Secondary Shaft - Inspection

1. Inspect the thrust needle bearings and the needle bearings for galling and rough movement.

2. Inspect the splines for excessive wear and damage.

3. Check the shaft bearing surface for scoring and excessive wear.

2. Secondary Shaft 1st Gear Axial Clearance - Inspection









1. Install the thrust needle bearing (A), the needle bearing (B), 1st gear (C), the thrust needle bearing (D), the 40 x 51.5 mm thrust washer (E), the 1st/3rd clutch (F), and the 3rd gear collar (G).

NOTE: Do not install the O-rings during inspection.

2. Install the idler gear (H), then install the transmission housing bearing (I) using the 42 mm bearing driver attachment and a press.

3. Install the conical spring washer (J) and the locknut (K).





4. Turn the secondary shaft assembly upside down, and set a dial indicator (A) on 1st gear (B).





5. Lift 1st gear (A) up while holding the secondary shaft, and use the dial indicator (B) to read the 1st gear axial clearance.

6. Measure the 1st gear axial clearance in at least three places while moving 1st gear. Use the average as the actual clearance.

Standard: 0.04-0.12 mm (0.0016-0.0047 in)

7. If the clearance is out of the standard, remove the 40 x 51.5 mm thrust washer and measure its height.

8. Select and install a new thrust washer, then recheck.







9. After replacing the thrust washer, make sure the clearance is within the standard.

10. Disassemble the installed parts from the secondary shaft.

3. Secondary Shaft 2nd Gear Axial Clearance - Inspection





1. Install the thrust needle bearing (A), the needle bearing (B), 2nd gear (C), the thrust needle bearing (D), the 37 x 58 mm thrust washer (E), and the 2nd clutch (F), then secure them with the set ring (G).

NOTE: Do not install the O-rings during inspection.









2. Measure the clearance between the set ring (A) and the 2nd clutch guide (B) using a feeler gauge (C), in at least three places. Use the average as the actual clearance.

Standard: 0.04-0.12 mm (0.002-0.004 in)

3. If the clearance is out of the standard, remove the 37 x 58 mm thrust washer, and measure its height.

4. Select and install a new thrust washer, then recheck.







5. After replacing the thrust washer, make sure the clearance is within the standard.

6. Disassemble the installed parts from the secondary shaft.

4. A/T Secondary Shaft





1. Install the thrust needle bearing (A), the needle bearing (B), 2nd gear (C), the thrust needle bearing (D), the selected 37 x 58 mm thrust washer (E), new O-rings (F), the 2nd clutch (G), a new snap ring (H), and new 29 mm sealing rings (I).





2. Install the thrust needle bearing (A), the needle bearing (B), 1st gear (C), the thrust needle bearing (D), the selected 40 x 51.5 mm thrust washer (E), and new O-rings (F).





3. Install the 1st/3rd clutch (A), the 3rd gear collar (B), the thrust needle bearing (C), the needle bearing (D), 3rd gear (E), and the thrust needle bearing (F).





4. Install the idler gear (A) in the direction shown on the secondary shaft (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.

5. Mainshaft - Inspection

1. Inspect the thrust needle bearings and the needle bearings for galling and rough movement.

2. Inspect the splines for excessive wear and damage.

3. Check the shaft bearing surface for scoring and excessive wear.

6. 5th Gear Axial Clearance - Inspection





1. Install the thrust needle bearing (A), 5th gear (B), the needle bearing (C), the thrust needle bearing (D), the 41 x 68 mm thrust washer (E), the 4th/5th clutch (F), the 4th gear collar (G), and the transmission housing bearing (H).

NOTE:
* Do not install the O-rings during inspection.
* The needle bearing contains the no-roller cavity (I); this is normal.

2. Install the idler gear (J) on the mainshaft using a press, then install the conical spring washer (K) and the locknut (L).





3. Set a dial indicator (A) on 5th gear (B).





4. Lift 5th gear (A) up while holding the mainshaft, and use the dial indicator (B) to read the 5th gear axial clearance.

5. Measure the 5th gear axial clearance in at least three places while moving 5th gear. Use the average as the actual clearance.

Standard: 0.04-0.10 mm (0.0016-0.0039 in)





6. If the clearance is out of the standard, remove the 41 x 68 mm thrust washer and measure its height.

7. Select and install a new thrust washer, then recheck.







8. After replacing the thrust washer, make sure the clearance is within the standard.

9. Disassemble the installed parts from the mainshaft.

7. A/T Mainshaft





1. Install new sealing rings (A), the needle bearing (B), and the set ring (C).





2. Install the thrust needle bearing (A), 5th gear (B), the needle bearing (C), the thrust needle bearing (D), the selected 41 x 68 mm thrust washer (E), and new O-rings (F).

NOTE: The needle bearing contains the no-roller cavity (G); this is normal.





3. Install the 4th/5th clutch (A), the 4th gear collar (B), the thrust needle bearing (C), the needle bearing (D), 4th gear (E), and the thrust needle bearing (F).

NOTE: The needle bearing contains the no-roller cavities (G); this is normal.

8. Mainshaft and Countershaft and Secondary Shaft Assembly





1. Be sure that each shaft is assembled. Also be sure that new sealing rings are installed on the mainshaft and the secondary shaft.

2. Join the mainshaft subassembly (A), the countershaft subassembly (B), and the secondary shaft subassembly (C) together, and install them.

NOTE: Do not bump the countershaft on the baffle plate (D).

3. Make sure the countershaft subassembly and the differential assembly (E) are clear of the baffle plate.

9. Selector Control Shaft





1. Install the selector control shaft (A).





2. Align the manual valve lever pin (A) on the selector control shaft (B) with the guide of the manual valve (C).





3. Hook the detent arm spring (A).

10. Selector Control Lever (Except 2WD of USA Produced Models)

Except 2WD of USA Produced Models





1. Install the control lever (A) over the selector control shaft (B).

2. Install the lock bolt (C) using a new lock washer (D).

3. Pry up the lock tab (E) of the lock washer against the bolt head.

11. Reverse Shift fork





1. Install the reverse shift fork (A) and the reverse selector (B) together.

2. Install the lock bolt (C) using a new lock washer (D).

3. Pry up the lock tab (E) of the lock washer against the bolt head.

12. A/T Countershaft Reverse Gear





1. Install the needle bearing (A).

2. Install the countershaft reverse gear (B).

13. Transmission Housing Secondary Shaft Bearing





1. Expand the snap ring using the snap ring pliers.

2. Install the secondary shaft bearing (A) part-way into the housing using the driver handle and the 52 x 55 mm bearing driver attachment.

3. Release the snap ring pliers, then push the bearing down into the transmission housing until the snap ring snaps in place around it.





4. After installing the bearing check that the snap ring (A) is seated in the bearing and the transmission housing groove, and that the snap ring end gap (B) is correct.

14. Transmission Housing Mainshaft Bearing





1. Expand the snap ring using the snap ring pliers.

2. Install the mainshaft bearing (A) part-way into the housing using the driver handle and the 78 x 80 mm bearing driver attachment.

3. Release the snap ring pliers, then push the bearing down into the transmission housing until the snap ring snaps in place around it.





4. After installing the bearing check that the snap ring (A) is seated in the bearing and the transmission housing groove, and that the snap ring end gap (B) is correct.

15. A/T Idler Gear/Idler Gear Shaft Assembly





1. Install the idler gear shaft/idler gear assembly (A).

2. Install the cotters (B), the cotter retainer (C), and a new snap ring (D) as shown.

16. Reverse Idler Gear





1. Install the reverse idler gear (A).





2. Lightly coat the reverse idler gear shaft (A), the needle bearing (B), and new O-rings (C) with lithium grease.

3. Assemble new O-rings and the 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 (E) cut out of the shaft with the D-shaped area (F) of the holder.





4. Install the reverse idler gear shaft/holder assembly (A).

17. Automatic Transmission Housing









1. Install the three dowel pins (A) and a new gasket (B).

2. Align the spring pin (C) of the selector control shaft (D) with the transmission housing groove (E).

NOTE: Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together, it will cause a faulty shift position signal or position due to the play between the selector control shaft and the transmission range switch.

3. Place the transmission housing (F) on the torque converter housing (G).

NOTE: Do not install the input shaft (mainshaft) speed sensor and the output shaft (countershaft) speed sensor before installing the transmission housing.

4. Wrap the tip of a screwdriver with tape so the reverse idler gear teeth do not get damaged. Engage the reverse idler gear (H) with the reverse gears (I) by rotating the idler gear using the screwdriver.

5. Make sure the transmission housing is securely seated so there is no clearance between the transmission housing and the torque converter housing.

6. Install the transmission hanger (J), and tighten the transmission housing mounting bolts (2WD: 19 bolts, AWD/4WD: 20 bolts) in at least two steps, in a crisscross pattern.

18. End Cover Idler Gear Assembly





1. Install the mainshaft holder onto the mainshaft.





2. Lubricate the following parts with ATF:

* Splines and threads of the mainshaft.
* Splines of the mainshaft idler gear.
* The old conical spring washer and the old locknut.

3. Install the mainshaft idler gear (A), the old conical spring washer (B), and the old locknut (C), and tighten the locknut to 225 Nm (23.0 kgm, 166 lbft).

NOTE:
* Do not tap the mainshaft idler gear to install.
* Use a torque wrench to tighten the locknut. Do not use an impact wrench.









4. Lubricate the following parts with ATF:

* Splines and threads of the countershaft.
* Splines of the park gear.
* The old conical spring washer and the old locknut.

5. Install the park gear (A), the old conical spring washer (B), and the old locknut (C).

6. Install the park lever spring (D), the park lever (E), and the park lever stop (F).

7. Install the lock bolt (G) using a new lock washer (H).

NOTE: Do not bend the lock tab of the lock washer until inspect the park lever stop.

8. Install the park pawl shaft (I), the park pawl spring (J), the park pawl (K), and the stop shaft (L).

9. Lift the park pawl up, and engage it with the park gear, and tighten the locknut to 225 Nm (23.0 kgm, 166 lbft).

NOTE:
* Do not tap the park gear to install.
* Use a torque wrench to tighten the locknut. Do not use an impact wrench.
* Countershaft locknut has left-hand threads.





10. Remove the old locknuts and the old conical spring washers from the mainshaft and the countershaft.

11. Lubricate the following parts with ATF:

* Splines and threads of the mainshaft, the countershaft, and the secondary shaft.
* New conical spring washers and new locknuts.
* Areas where the conical spring washers contact the mainshaft idler gear and the park gear.

12. Install new conical spring washers (A) in the direction shown.

13. Install a new mainshaft locknut (B), a new countershaft locknut (C), and a new secondary shaft locknut (D).

14. Tighten the locknuts to 167 Nm (17.0 kgm, 123 lbft).

NOTE:
* Use a torque wrench to tighten the locknut. Do not use an impact wrench.
* The countershaft and secondary shaft locknuts have left-hand threads.

15. Remove the mainshaft holder.





16. Stake the locknuts into the shafts to a depth (A) of 0.7-1.3 mm (0.027-0.051 in) using a 3.5 mm punch (B).





17. Set the park lever in the P position.

18. Measure the distance (A) between the center of the park pawl shaft (B) and the center of the park lever roller pin (C) as shown.

Standard: 57.7-58.7 mm (2.272-2.311 in)





19. If the measurement is out of the standard, select and install the appropriate park lever stop (A) from the table.






20. After replacing the park lever stop, make sure the distance is within the tolerance.





21. Pry up the lock tab (A) of the lock washer against the bolt head.

19. ATF Feed Pipe/Lubrication Pipe





1. Install the 6 x 201 mm ATF pipe (A).

2. Install the ATF lubrication pipe (B).

3. Install the 8 x 220 mm ATF pipe (C).

4. Install the 8 x 198 mm ATF pipes (D).

20. A/T Shift Solenoid Wire Harness - Reconnection





1. Connect the shift solenoid valve connectors:

* BLU wire to shift solenoid valve A.
* ORN wire to shift solenoid valve B.
* GRN wire to shift solenoid valve C.
* YEL, WHT, and WHT wires to shift solenoid valve D.
* RED wire to shift solenoid valve E.