Removal

Torque Converter Housing Countershaft Bearing Replacement

















*: Must be used with commercially available 3/8''-16 slide hammer

Removal

NOTE: The illustration shows AWD/4WD transmission.

1. Transmission Range Switch Cover





1. Remove the transmission range switch cover (A).

2. Transmission Range Switch





1. Remove the transmission range switch (A).

3. Transmission Range Switch Subharness





1. Remove the transmission range switch subharness (A).

2. Remove the clamp brackets (B).

4. Transmission End Cover





1. Remove the end cover (A), the dowel pins (B), the O-rings (C), and the gasket (D).

5. Input Shaft (Mainshaft) Speed Sensor





1. Remove the input shaft (mainshaft) speed sensor (A).

2. Remove the O-ring (B) from the input shaft (mainshaft) speed sensor.

6. Output Shaft (Countershaft) Speed Sensor





1. Remove the output shaft (countershaft) speed sensor (A) and the sensor washer (B).

2. Remove the O-ring (C) from the output shaft (countershaft) speed sensor.

7. A/T Clutch Pressure Control Solenoid Valve A





1. Remove A/T clutch pressure control solenoid valve A.

2. Remove the 35 mm ATF pipe (B), the ATF joint pipes (C), the O-rings (D), and the gasket (E).

8. A/T Clutch Pressure Control Solenoid Valve B and C





1. Remove the clamp bracket (A) and A/T clutch pressure control solenoid valves B and C.

2. Remove the ATF joint pipes (D), the O-rings (E), and the gasket (F).

9. ATF Inlet Line





1. Remove the banjo bolt (A) and the sealing washers (B).

2. Remove the ATF inlet line (C).

10. ATF Outlet Line





1. Remove the banjo bolt (A) and the sealing washers (B).

2. Remove the ATF outlet line (C).

11. Dipstick Guide Tube





1. Remove the ATF dipstick guide tube (A).

2. Remove the O-ring (B) from the ATF dipstick guide tube.

12. A/T Shift Solenoid Cover





1. Remove the shift solenoid valve cover (A), the dowel pins (B), and the gasket (C).

13. A/T Shift Solenoid Wire Harness - Disconnection





1. Disconnect the connectors.

14. ATF Feed Pipe/Lubrication Pipe





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

2. Remove the ATF lubrication pipe (B).

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

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

15. End Cover Idler Gear Assembly





1. Install the mainshaft holder onto the mainshaft.

2. Engage the park pawl with the park gear.





3. Using a chisel, cut the lock tab (A) of the locknut (B).

NOTE: Keep all of the chiseled particles out of the transmission.





4. Remove the locknuts (A) and the conical spring washers (B) from each shaft.

NOTE:
* The countershaft and secondary shaft locknuts have left-hand threads.
* Keep all of the chiseled particles out of the transmission.
* Clean the old locknuts; they are used to install the press fit idler gears and park gear.

5. Remove the mainshaft holder.





6. Remove the park pawl (A), the park pawl spring (B), the park pawl shaft (C), and the stop shaft (D).

7. Pry down the lock tab (E) of the lock washer (F).

8. Remove the lock bolt (G) and the lock washer.

9. Remove the park lever (H), the park lever stop (I), and the park lever spring (J).





10. Place a spacer (A) on the countershaft (B).

11. Set a commercially available bearing puller (C) on the park gear (D).

12. Remove the park gear.





13. Install a puller (A) with two 6 x 1.0 mm bolts (B) on the mainshaft idler gear (C).

14. Set a spacer (D) between the puller and the mainshaft (E).

15. Remove the mainshaft idler gear.

16. Automatic Transmission Housing









1. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C).

NOTE: Do not squeeze the end of the selector control shaft tips together when turning the control 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.

2. Remove the transmission housing mounting bolts (D) (2WD: 19 bolts, AWD/4WD: 20 bolts).

3. Install the housing puller over the mainshaft.

4. Remove the transmission housing (E) using the housing puller.

5. Remove the dowel pins (F) and the gasket (G).

17. A/T Countershaft Reverse Gear





1. Remove the countershaft reverse gear (A).

2. Remove the needle bearing (B).

18. Reverse Shift fork





1. Pry down the lock tab (A) of the lock washer (B).

2. Remove the lock bolt (C) and the lock washer.

3. Remove the reverse shift fork (D) and the reverse selector (E) together.

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

Except 2WD of USA Produced Models





1. Pry down the lock tab (A) of the lock washer (B).

2. Remove the lock bolt (C) and the lock washer.

3. Remove the selector control lever (D).

20. Selector Control Shaft





1. Unhook the detent arm spring (A).





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





3. Remove the selector control shaft (A).

21. Mainshaft and Countershaft and Secondary Shaft Assembly





1. Turn the detent arm (A) away from the countershaft (B).





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

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

22. Differential Assembly





1. Remove the baffle plate (A).

2. Remove the differential assembly (B).

23. Regulator Valve Body





1. Remove ATF joint pipe A.

2. Remove ATF joint pipe B.





3. Remove the regulator valve body (A).





4. Remove the stator shaft (A).

5. Remove the O-ring (B) from the stator shaft.

6. Remove the stator shaft stop (C).





7. Remove the regulator separator plate (A) and the dowel pins (B).

24. ATF Strainer





1. Remove the ATF strainer (A) and the O-ring (B).





2. Clean the inlet opening (A) of the ATF strainer (B) thoroughly with compressed air, then check that it is in good condition and that the inlet opening is not clogged.

3. Test the ATF strainer by pouring clean ATF through the inlet opening, and replace it if it is clogged or damaged.

25. Servo Body





1. Remove the servo body (A).





2. Remove the servo separator plate (A) and the dowel pins (B).

26. Main Valve Body





1. Remove the cooler check valve spring (A) and the cooler check valve (B).

2. Remove the main valve body (C).

NOTE: Do not let the check balls (D) fall out, and do not use a magnet to remove the check balls, it may magnetize them.





3. Remove the ATF pump driven gear shaft (A).

4. Remove the ATF pump drive gear (B) and the ATF pump driven gear (C).





5. Remove the main separator plate (A) and the dowel pins (B).

27. Torque Converter Housing Countershaft Bearing









1. Remove the countershaft bearing (A) using the 25-40 mm adjustable bearing puller and a commercially available 3/8''-16 slide hammer (B).

2. Remove the ATF guide plate (C), and check it for wear and damage. If the guide plate is worn or damaged, replace it.