Automatic Transmission Disassembly and Reassembly
Special Tools Required
Image Description/Tool Number
310230.png Snap Ring Pliers 07LGC-0010100
310251.png Mainshaft Holder Set 07PAB-0010001

NOTE: Inspect and adjust the differential carrier bearing preload whenever the transmission housing, the torque converter housing, or the differential carrier are removed.

1. Dipstick Tube - Remove
1.
Remove the ATF dipstick (A).
2.
Remove the dipstick tube (B) with the O-ring (C).

2. Transmission Range Switch - Remove
Remove the transmission range switch (A).


3. Control Lever - Remove
1.
Shift the transmission in the P position by rotating the control lever.
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 control shaft and the transmission range switch.
2.
Pry down the lock tab (A) of the lock washer (B).
3.
Remove the control lever (C) with the lock washer.

4. Input Shaft (Mainshaft) Speed Sensor - Remove
Remove the input shaft (mainshaft) speed sensor (A) with the O-ring (B).


5. Output Shaft (Countershaft) Speed Sensor - Remove
Remove the output shaft (countershaft) speed sensor (A) with the O-ring (B).


6. ATF Temperature Sensor - Remove
Remove the ATF temperature sensor (A) with the O-ring (B).


7. ATF Outlet Line/ATF Hose Assembly - Remove
Remove the ATF outlet line/ATF hose assembly (A) with the sealing washers (B).


8. ATF Inlet Line/ATF Hose/ATF Filter Assembly - Remove
Remove the ATF inlet line/ATF hose/ATF filter assembly (A) with the sealing washers (B).


9. ATF Pipe Assembly - Remove
Remove the ATF pipe assembly (A).


10. Transmission Hanger - Remove
Remove transmission hanger A and transmission hanger B.


11. End Cover - Remove
Remove the mainshaft end cover (A), the third shaft end cover (B), and the end covers (C) (two), with the O-rings (D).


12. Transmission Fluid Pressure Switch A (2nd Clutch) - Remove
Remove transmission fluid pressure switch A (2nd clutch) with the sealing washer (B).

NOTE: Loosen the switch by gripping the metal part, not the plastic part.


13. Transmission Fluid Pressure Switch D (5th Clutch) - Remove
Remove transmission fluid pressure switch D (5th clutch) with the sealing washer (A).

NOTE: Loosen the switch by gripping the metal part, not the plastic part.


14. Transmission Fluid Pressure Switch C (4th Clutch) - Remove
Remove transmission fluid pressure switch C (4th clutch) with the sealing washer (A).

NOTE: Loosen the switch by gripping the metal part, not the plastic part.


15. Shift Solenoid Valve C - Remove
Remove shift solenoid valve C with the O-rings (A).


16. Secondary Valve Body - Remove
1.
Remove the secondary valve body (D).
NOTE: Do not disassemble the secondary valve body. If any problem occurs, replace the assembly.
2.
Remove ATF pipes A, B, and C, with the O-rings (E) and the gasket (F).

17. Mainshaft Holder - Set
Install the mainshaft holder onto the mainshaft.


18. Locknut - Remove
1.
Using a chisel, cut the lock tab (A) of the locknut (B) securing the mainshaft and third shaft locknuts.
NOTE:
Keep all of the chiseled particles out of the transmission.
The illustration shows the mainshaft locknut.
2.
Remove the mainshaft locknut (A) and the third shaft locknut (B).
NOTE: The third shaft locknut has left-hand threads.
3.
Pry the lock washers (C), then remove them.
NOTE: Keep all of the particles out of the transmission.

19. Mainshaft Holder - Remove
Remove the mainshaft holder.


20. Transmission Housing - Remove
1.
Remove the transmission housing mounting bolts (A: 8 mm bolts, B: 10 mm bolts) with the skid block (C).
2.
While expanding the snap ring of the countershaft bearing using the snap ring pliers, lift the transmission housing (A).
3.
Release the snap ring pliers.
4.
Remove the transmission housing (A), two dowel pins (B), and the gasket (C).

21. ATF Joint Pipe - Remove
Remove ATF joint pipes A and B with the O-rings (C).


22. ATF Strainer - Remove
1.
Remove the ATF strainer (A) with 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.
Check the ATF strainer for clogs, debris, or damage. If the strainer is clogged or damaged, replace it.

23. ATF Pipe - Remove
1.
Remove the 10 x 70 mm ATF joint pipe (A).
2.
Remove the ATF lubrication pipe (B).

24. Reverse Gear and Reverse Selector Hub - Remove
1.
Pry down the lock tab (A) of the lock washer (B).
2.
Remove the bolt (C) and the lock washer.
3.
Remove the reverse gear (A), the reverse selector hub (B), the shift fork (C), and the baffle plate (D) together.

25. A/T Shaft Assembly - Remove
1.
Remove the mainshaft subassembly (A), the countershaft subassembly (B), the secondary shaft subassembly (C), and the idler gear shaft (D) together.
2.
Remove the needle bearing (E).
3.
Remove the third shaft (A).

26. Parking Holder - Remove
Remove the parking holder (A).


27. Selector Control Shaft - Remove
1.
Unhook the detent arm spring (A).
2.
Remove the detent arm (A) and the detent arm shaft (B).
3.
Remove the selector control shaft (A).

28. Differential Assembly - Remove
Remove the differential assembly (A).


29. Oil Catch Plate - Remove
Remove the oil catch plate (A).


30. Air Check Valve (2nd/5th) - Remove
Remove the 2nd air check valve (A) and the 5th air check valve (B).


31. Cooler Retainer Cap - Remove
Remove the cooler retainer cap (A).


32. Air Check Valve (3rd/6th) - Remove
Remove the 3rd air check valve (A) and the 6th air check valve (B).


33. Stator Shaft - Remove
Remove the stator shaft support (A), the stator shaft (B), the stator shaft stop (C), two dowel pins (D), and the O-rings (E).


34. Manual Valve Body - Remove
Remove the manual valve body (A) (seven bolts), two dowel pins (B), the manual separator plate (C), and two check balls (D).

NOTE:
Do not let the check balls fall out, and do not use a magnet to remove the check balls, it may magnetize them.
Do not disassemble the manual valve body. If any problem occurs, replace the assembly.

35. Regulator Valve Body - Remove
Remove the regulator valve body (A) (eight bolts), two dowel pins (B), and the regulator separator plate (C).

NOTE: Do not disassemble the regulator valve body. If any problem occurs, replace the assembly.


36. Air Check Valve (4th/Reverse) - Remove
Remove the 4th/reverse air check valve (A).


37. Main Valve Body - Remove
1.
Remove the main valve body (A) (eight bolts).
2.
Remove the ATF pump driven gear shaft (B), then remove the ATF pump driven gear (C) and the ATF pump drive gear (D).
3.
Remove two dowel pins (E) and the main separator plate (F).

38. ATF Magnet - Remove
1.
Remove the ATF magnet (A).
2.
Clean the ATF magnet, then reinstall it in the torque converter housing.

1. Transmission - Exploded View

Exploded View





Exploded View





Exploded View





Exploded View



NOTE:
Refer to the Exploded View as needed during the following procedure.
Apply a light coat of clean ATF on all tubes, O-rings, and moving parts before reassembly.
Inspect and adjust the differential carrier bearing preload whenever the transmission housing, the torque converter housing, or the differential carrier are removed.

1. ATF Magnet - Install
1.
Make sure that the ATF magnet (A) is cleaned.
2.
Clean the ATF magnet if necessary, then install the ATF magnet.

2. Main Valve Body - Install
1.
Install the main separator plate (A) and two dowel pins (B).
2.
Install the ATF pump drive gear (C), the ATF pump driven gear (D), and the ATF pump driven gear shaft (E). Install the ATF pump driven gear with its grooved and chamfered side facing down.
3.
Install the main valve body (F) (eight bolts).
4.
Make sure the ATF pump drive gear (A) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (B) moves smoothly in the axial and normal operating direction.
5.
If the ATF pump drive gear and 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. 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.

3. Air Check Valve (4th/Reverse) - Install
Install the 4th/reverse air check valve (A).


4. Regulator Valve Body - Install
1.
Install the regulator separator plate (A) and two dowel pins (B).
2.
Install the regulator valve body (C) (eight bolts).

5. Manual Valve Body - Install
1.
Install two check balls (A).
2.
Install the manual separator plate (B) and two dowel pins (C).
3.
Install the manual valve body (D) (seven bolts).

6. Stator Shaft - Install
1.
Install two dowel pins (A).
2.
Install the stator shaft (B) with three new O-rings (C).
3.
Install the stator shaft support (D) (four bolts).
4.
Install the stator shaft stop (E).

7. Air Check Valve (3rd/6th) - Install
Install the 3rd air check valve (A) and the 6th air check valve (B).


8. Cooler Retainer Cap - Install
Install the cooler retainer cap (A).


9. Air Check Valve (2nd/5th) - Install
Install the 2nd air check valve (A) and the 5th air check valve (B).


10. Oil Catch Plate - Install
Install the oil catch plate (A).


11. Differential Assembly - Install
Install the differential assembly (A).


12. Selector Control Shaft - Install
1.
Install the selector control shaft (A).
2.
Align the control lever pin (A) with the manual valve guide (B).
3.
Install the detent arm (A) and the detent arm shaft (B).
4.
Hook the detent arm spring (A).

13. Parking Holder - Install
Install the parking holder (A).


14. A/T Shaft Assembly - Install

2.
Install the third shaft (A).

4.
Install the thrust needle bearing (A).
5.
Join the mainshaft subassembly (B), the countershaft subassembly (C), the secondary shaft subassembly (D), and the idler gear shaft subassembly (E) together, then install them.

6.
Install the 27.5 x 41 x 2.5 mm thrust needle bearing (F) and the 41.5 mm washer (G) on the top of the idler gear shaft.

15. Reverse Gear and Reverse Selector Hub - Install
1.
Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole of the shift fork (B).
2.
Install the baffle plate (C), the shift fork, the reverse selector hub (D), and the reverse gear (E) together.
3.
Secure the shift fork (A) using a new lock washer (B), then pry up the lock tab (C) of the lock washer against the bolt head.

16. ATF Pipe - Install
1.
Install the ATF lubrication pipe (A).
2.
Install the 10 x 70 mm ATF joint pipe (B).

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


18. ATF Joint Pipe - Install
Install ATF joint pipes A and B using new O-rings (C).


19. Transmission Housing - Install
1.
Install two dowel pins (A) and a new gasket (B).
2.
Place the transmission housing (C).
3.
Wrap a screwdriver tip with tape to prevent damaging the reverse idler gear teeth. Engage the reverse idler gear with the reverse gears by rotating the idler gear using the screwdriver.
4.
While expanding the snap ring of the countershaft bearing using the snap ring pliers, install the transmission housing onto the bearing part-way.

5.
Release the snap ring pliers, and push down on the transmission housing until it bottoms and snap ring snaps into place on the countershaft bearing snap ring groove.
6.
Install the transmission housing mounting bolts (A: 8 mm bolts, B: 10 mm bolts) along with the skid block (C), and tighten the bolts in at least two steps in a crisscross pattern to the specified torque.

20. Control Lever - Install
1.
Install the control lever (A) over the selector control shaft (B).
2.
Secure the control lever using a new lock washer (C), then pry up the lock tab (D) of the lock washer against the bolt head.
3.
Shift the transmission in the P position by rotating the control lever.
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 control shaft and the transmission range switch.

21. Mainshaft Holder - Set
Install the mainshaft holder onto the mainshaft.


22. Locknut - Install
1.
Install the old lock washers (A) with the marked side (B) up over the mainshaft (C) and the third shaft (D).
2.
Apply ATF to surfaces of the old lock washers and the old locknuts (E).
3.
Install the old locknuts, then tighten them to seat the lock washers to the specified torque.
NOTE: The third shaft locknut has left-hand threads.
4.
Remove the old locknuts and the old lock washers.
5.
Install new lock washers (A) with the marked side (B) up over the mainshaft (C) and the third shaft (D).
6.
Install a new mainshaft locknut (E) and a new third shaft locknut (F), then tighten them to the specified torque.
NOTE:
Do not rotate the locknuts in the reverse direction after the locknuts are seated to the lock washers.
The third shaft locknut has left-hand threads.
7.
Stake the locknuts to a depth (A) of 0.7?1.3 mm (0.028?0.051 in) using a 3.5 mm punch (B).

23. Mainshaft Holder - Remove
Remove the mainshaft holder.


24. Secondary Valve Body - Install
1.
Apply ATF to new O-rings (D), then install the O-rings over ATF pipes A, B, and C.
2.
Install the ATF pipes with the filter ends (E) facing the secondary valve body (F) into the transmission.
NOTE: Do not drop the ATF pipes into the transmission. If an ATF pipe is dropped into the transmission, the transmission will need to be disassembled.
3.
Install the secondary valve body using a new gasket (G) while aligning the ATF pipes with the pipe holes on the secondary valve body.

25. Shift Solenoid Valve C - Install
Install shift solenoid valve C using new O-rings (A).


26. Transmission Fluid Pressure Switch C (4th Clutch) - Install
Install transmission fluid pressure switch C (4th clutch) using a new sealing washer (A).

NOTE: Tighten the switch by gripping the metal part, not the plastic part.


27. Transmission Fluid Pressure Switch D (5th Clutch) - Install
Install transmission fluid pressure switch D (5th clutch) using a new sealing washer (A).

NOTE: Tighten the switch by gripping the metal part, not the plastic part.


28. Transmission Fluid Pressure Switch A (2nd Clutch) - Install
Install transmission fluid pressure switch A (2nd clutch) using a new sealing washer (B).

NOTE: Tighten the switch by gripping the metal part, not the plastic part.


29. End Cover - Install
1.
Install the mainshaft end cover (A) using a new O-ring (B).
2.
Install the third shaft end cover (C) using a new O-ring (D).
3.
Install the end covers (E) using new O-rings (F).

30. Transmission Hanger - Install
Install transmission hanger A and transmission hanger B.


31. ATF Pipe Assembly - Install
Install the ATF pipe assembly (A).


32. ATF Inlet Line/ATF Hose/ATF Filter Assembly - Install
Install the ATF inlet line/ATF hose/ATF filter assembly (A) using new sealing washers (B).


33. ATF Outlet Line/ATF Hose Assembly - Install
Install the ATF outlet line/ATF hose assembly (A) using new sealing washers (B).


34. ATF Temperature Sensor - Install
Install the ATF temperature sensor (A) using a new O-ring (B).


35. Output Shaft (Countershaft) Speed Sensor - Install
Install the output shaft (countershaft) speed sensor (A) using a new O-ring (B).


36. Input Shaft (Mainshaft) Speed Sensor - Install
Install the input shaft (mainshaft) speed sensor (A) using a new O-ring (B).


37. Transmission Range Switch - Install
1.
Shift the transmission into the N position by rotating the control lever from the P position.
NOTE: Do not use the 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 control shaft and the transmission range switch.
2.
Set the transmission range switch (A) to the N position. Align the cutouts (B) on the rotary-frame with the N positioning cutouts (C) on the transmission range switch, then put a 2.0 mm (0.079 in) feeler gauge blade (D) in the cutouts to hold the transmission range 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 while holding it in the N position with the 2.0 mm (0.079 in) blade (B).
4.
Tighten the bolts on the transmission range switch while you continue to hold the N position.
NOTE: Do not move the transmission range switch when tightening the bolts.
5.
Remove the feeler gauge.

38. Dipstick Tube - Install
1.
Install the ATF dipstick tube (A) using a new O-ring (B).
2.
Install the ATF dipstick (C).