Disassembly

A/T Countershaft Disassembly, Reassembly, and Inspection

















View

1. A/T Countershaft Exploded View

Exploded View





Disassembly

1. Transmission Range Switch Cover





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

2. Transmission Range Switch





1. Disconnect the connector (A).

2. Remove the transmission range switch (B).

3. Transmission Range Switch Subharness





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

2. Remove the clamp brackets (B).

4. ATF Warmer Bracket





1. Remove the ATF warmer bracket (A).

5. Transmission End Cover





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

6. Input Shaft (Mainshaft) Speed Sensor





1. Remove the input shaft (mainshaft) speed sensor (A) with the O-ring (B).

7. Output Shaft (Countershaft) Speed Sensor





1. Remove the output shaft (countershaft) speed sensor (A) with the O-ring (B).

8. A/T Clutch Pressure Control Solenoid Valve A





1. Remove A/T clutch pressure control solenoid valve A with the ATF joint pipes (B), the O-rings (C), the 35 mm ATF pipe (D), and the gasket (E).

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





1. Remove A/T clutch pressure control solenoid valves B and C with the ATF joint pipes (A), the O-rings (D), the 50 mm ATF pipe (E), and the gasket (F).

10. A/T Solenoid Cover





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

11. A/T Shift Solenoid Wire Harness - Disconnection





1. Disconnect the connectors.

12. ATF Pipe





1. Remove the 6 x 199 mm ATF pipe (A).

2. Remove the 8 x 192.5 mm ATF pipe (B).

3. Remove the 8 x 180.5 mm ATF pipes (C).

4. Remove the ATF lubrication pipe (D).

13. 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 of the lock washer (E).

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

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





10. Remove the snap ring (A) securing the idler gear to the idler gear shaft.





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

12. Set a spacer (D) between the puller and the idler gear shaft (E).

13. Remove the idler gear shaft idler gear.





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

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

16. Remove the mainshaft idler gear.





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

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

19. Remove the park gear.





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

21. Set a spacer (D) between the puller and the secondary shaft (E).

22. Remove the secondary shaft idler gear.

14. A/T 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.

2. Install the housing puller over the countershaft.

NOTE: If the top arm of your housing puller is too short, replace it with 205 mm housing puller arm 07SAC-P0Z0101.

3. Remove the transmission housing mounting bolts (D).

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

15. A/T Countershaft Reverse Gear





1. Remove the countershaft reverse gear (A).

2. Remove the needle bearing (B).

16. Shift fork Shaft





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

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

3. Remove the reverse shift fork (C) with the reverse selector (D) together.

17. A/T Mainshaft and Countershaft and Secondary Shaft Assembly





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

18. A/T Countershaft





1. Place 4th-5th gear (A) on a press, and set a spacer (B) between the countershaft and the press to prevent damaging the countershaft.

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

2. Support the bottom of the countershaft with one hand, then press the countershaft out of the press-fitted reverse selector hub (C) with 4th-5th gear, and remove the countershaft while holding the underside the countershaft. The countershaft will drop down after pressing it out of the press-fitted reverse selector hub.





3. Remove the needle bearing (A), the snap ring (B), the 33 x 45 x 7.8 mm collar (C), and the 29 mm cotters (D).





4. Remove the 33.2 x 40 x 51.8 mm collar (A), 3rd gear (B), 2nd gear (C), and 1st gear (D).