Installation

Torque Converter Housing Differential Carrier Bearing Outer Race Replacement

Installation

NOTE:
* The bearing and the bearing outer race should be replaced as a set.
* Replace the bearing with a new one whenever the outer race is replaced.
* Adjust bearing preload after replacing the bearing and the outer race.
* Apply a light coat of clean ATF on all moving parts before installation.

1. Torque Converter Case Differential Carrier Bearing Outer Race





1. Install the 80 mm thrust washer (A) and the bearing outer race (B).





2. Install the bearing outer race securely in the torque converter housing using the driver handle and the 78 x 80 mm bearing driver attachment.

2. A/T Main Valve Body





1. Install the main separator plate (A) and the dowel pins (B).









2. Install the ATF pump drive gear (A) and the ATF pump driven gear (B).

NOTE: Install the ATF pump driven gear with its grooved and chamfered side facing down.

3. Install the ATF pump driven gear shaft (C).









4. Install the main valve body (A).

NOTE: Make sure that the check balls (B) are in the main valve body.

5. Make sure the ATF pump drive gear (C) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (D) moves smoothly in the axial and normal operating direction.

6. If the ATF pump drive gear and the ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torque, then recheck.

NOTE: Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft.

7. Install the cooler check valve (E) and the cooler check valve spring (F).





8. Install ATF joint pipe A.

9. Install ATF joint pipe B.

3. A/T Servo Body





1. Install the servo separator plate (A) and the dowel pins (B).





2. Install the servo body (A).





3. Install the detent arm (A) and the arm collar (B)

4. Install a new lock washer (C) by aligning its cutout (D) with the projection (E).

5. Install and tighten the bolt, then bend the lock tab (F) of the lock washer against the bolt head.

4. ATF Strainer





1. Install the ATF strainer (A) using a new O-ring (B).

5. 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).

6. Shift Solenoid Valve





NOTE:
* Do not hold the shift solenoid valve connector to install the shift solenoid valves. Be sure to hold the shift solenoid valve body.
* A new shift solenoid valve comes with new O-rings. If you install a new solenoid valve, use the O-rings provided on it.

1. Install shift solenoid valve B (black connector) using new O-rings (C) by holding the shift solenoid valve body; be sure that the mounting bracket contacts to the servo body.

NOTE: Do not install shift solenoid valve A before installing shift solenoid valve B. If shift solenoid valve A is installed before installing shift solenoid valve B, it may damage to hydraulic control system.

2. Install shift solenoid valve A (brown connector) using new O-rings (D) by holding the shift solenoid valve body; be sure that the mounting bracket contacts to the bracket of shift solenoid valve B.





3. Install shift solenoid valve C (brown connector) using new O-rings (A) by holding the shift solenoid valve body; be sure that the mounting bracket contacts to the servo body.

4. Install shift solenoid valve D (black connector) using new O-rings (B) by holding the shift solenoid valve body; be sure that the mounting bracket contacts to the servo body.

7. A/T Regulator Valve Body





1. Install the regulator separator plate (A) and the dowel pins (B).





2. Install the stator shaft (A) using a new O-ring (B).

3. Install the stator shaft stop (C).





4. Install the regulator valve body (A).

8. A/T Differential Assembly





1. Install the differential assembly (A).

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





1. Assemble the mainshaft, the countershaft, and the secondary shaft.

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

10. Shift fork Shaft





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

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

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

11. A/T Countershaft Reverse Gear





1. Install the needle bearing (A).

2. Install the countershaft reverse gear (B).

12. A/T 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 and tighten the transmission housing mounting bolts in at least two steps, in a crisscross pattern.

13. 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 216 Nm (22.0 kgfm, 159 lbfft).

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 secondary shaft and the idler gear shaft.
* Splines of the secondary shaft idler gear.
* The old conical spring washer and the old locknut.

5. Install the secondary shaft idler gear (A).

NOTE: Do not tap the idler gear to install.

6. Install the idler gear shaft idler gear (B).

NOTE: Do not tap the idler gear to install.





7. Set the gear installer set on the idler gear shaft and the idler gear.

8. Tighten the installer nut to install the idler gear part-way.

NOTE: The installer nut has left-hand threads.





9. Install the old conical spring washer (A) and the old locknut (B), and tighten the locknut to 225 Nm (23.0 kgfm, 166 lbfft).

NOTE:
* Do not tap the idler gears to install.
* Use a torque wrench to tighten the locknut. Do not use an impact wrench.
* Secondary shaft locknut has left-hand threads.





10. Retighten the installer nut to seat the idler gear in the idler gear shaft until it stops.

11. Remove the gear installer set.





12. Install a new snap ring (A).

13. Check that the snap ring is seated securely into the groove.









14. 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.

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

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

17. 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.

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

19. Lift the park pawl up, and engage it with the park gear, and tighten the locknut to 225 Nm (23.0 kgfm, 166 lbfft).

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





20. Remove the old locknuts and the old conical spring washers from the mainshaft, the countershaft, and the secondary shaft.

21. 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, the secondary shaft idler gear, and the park gear.

22. Install new conical spring washers (A) with facing stamped mark side up in the direction shown.

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

24. Tighten the mainshaft locknut to 155 Nm (15.8 kgfm, 114 lbfft).
Tighten the countershaft and secondary shaft locknuts to 167 Nm (17.0 kgfm, 123 lbfft).

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.

25. Remove the mainshaft holder.





26. 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).





27. Set the park lever in the P position.

28. Measure the distance (A) between the park pawl shaft center (B) and the extension line (C) connected centers of the park lever roller pin (D) and the control shaft (E) in the vertical direction from the extension line.

Standard: 46.8-47.8 mm (1.843-1.882 in)

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











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





31. Bend the lock tab (A) of the lock washer against the bolt head.

14. ATF Pipe





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

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

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

4. Install the ATF lubrication pipe (D).

15. A/T Shift Solenoid Wire Harness - Reconnection





1. Connect the shift solenoid valve connectors:

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

16. A/T Solenoid Cover





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

17. ATF Filter Assembly

1. Install the ATF inlet line/ATF hose/ATF filter assembly (A).






2. Install the banjo bolt (B) using new sealing washers (C).

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 down and the white side up on the transmission housing.

3. Install the 50 mm ATF pipe (D) and the ATF joint pipes (E).

4. Install new O-rings (F) over the ATF joint pipes.

5. Install A/T clutch pressure control solenoid valves B and C.

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 down and the white side up on the transmission housing.

3. Install the 35 mm ATF pipe (C) and the ATF joint pipes (D).

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

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

20. Output Shaft (Countershaft) Speed Sensor (A/T)





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

21. Input Shaft (Mainshaft) Speed Sensor





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

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).

23. ATF Warmer Bracket





1. Install the ATF warmer bracket (A).

24. Transmission Range Switch Subharness





1. Install the clamp brackets (A).

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

25. 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.

26. Transmission Range Switch Cover





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