Inspection, Reassembly

A/T Mainshaft Disassembly, Reassembly, and Inspection

















View

1. A/T Mainshaft Exploded View

Exploded View






Inspection

1. 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.

2. 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.

Reassembly

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

1. 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.

2. 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.

3. 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).

4. 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.

5. 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.

6. A/T Countershaft Reverse Gear





1. Install the needle bearing (A).

2. Install the countershaft reverse gear (B).

7. 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.

8. 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.

9. 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).

10. 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.

11. 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.

12. 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).

13. 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.

14. A/T Shift Solenoid Cover





1. Install the shift solenoid valve cover (A) with the dowel pins (B) and a new gasket (C).

15. Dipstick Guide Tube





1. Install a new O-ring (A) on the ATF dipstick guide tube (B).

2. Install the ATF dipstick guide tube.

16. ATF Outlet Line





1. Install the ATF outlet line (A) using new sealing washers (B).

17. ATF Inlet Line





1. Install the ATF inlet line (A) using new sealing washers (B).

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





1. Clean the mounting surfaces and the fluid passages of the solenoid valve body and the transmission housing.

2. Install a new gasket (A) with the blue side toward the transmission housing, and Install the ATF joint pipes (D).

3. Install new O-rings (E) over the ATF joint pipes.

4. Install A/T clutch pressure control solenoid valves B and C with the clamp bracket (F).

19. A/T Clutch Pressure Control Solenoid Valve A





1. Clean the mounting surfaces and the fluid passages of the solenoid valve body and the transmission housing.

2. Install a new gasket (B) with the blue side toward the transmission housing, and install the 35 mm ATF pipe (C) and the ATF joint pipes (D).

3. Install new O-rings (E) over the ATF joint pipes.

4. Install A/T clutch pressure control solenoid valve A.

20. Output Shaft (Countershaft) Speed Sensor





1. Install a new O-ring (A) on the output shaft (countershaft) speed sensor (B).

2. Install the output shaft (countershaft) speed sensor and the sensor washer (C).

21. Input Shaft (Mainshaft) Speed Sensor





1. Install a new O-ring (A) on the input shaft (mainshaft) speed sensor (B).

2. Install the input shaft (mainshaft) speed sensor.

22. Transmission End Cover





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

2. Install new O-rings (C) over the ATF pipes.

3. Install the end cover (D), and tighten the three special bolts (E) and the 6 x 1.0 mm bolts (F) (12 bolts).

23. Transmission Range Switch Subharness





1. Install the clamp brackets (A).

2. Install the transmission range switch subharness (B).

24. Transmission Range Switch





1. Make sure the selector control shaft is in the N position. If necessary, move the selector control shaft to the N position.

NOTE: Do not use the selector control shaft to adjust the shift position. If the selector control shaft tips are squeezed together it will cause a faulty signal or position due to play between the selector control shaft and switch.





2. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.079 in) feeler gauge blade (D) in the cutouts to hold the switch in the N position.

NOTE: Be sure to use a 2.0 mm (0.079 in) blade or equivalent to hold the switch in the N position.





3. Install the transmission range switch (A) gently on the selector control shaft (B) while holding it in the N position with the 2.0 mm (0.079 in) blade (C).





4. Tighten the bolts on the transmission range switch (A) while you continue holding the N position.

NOTE: Do not move the transmission range switch when tightening the bolts.

5. Remove the feeler gauge (B).

6. Check the connector (C) for corrosion, dirt, or oil, and clean or repair if necessary, then connect the connector securely.

25. Transmission Range Switch Cover





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