Part 1

TRANSMISSION HOUSING/LOWER VALVE BODY ASSEMBLY

Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the lower valve body assembly, replace the following:
- O-rings
- ATF pan gasket

CAUTION: Do not turn over the transmission before removing the ATF pan.

1. Remove the shift control solenoid/linear solenoid harness connector stop.
2. Remove the ATF pan (14 bolts).
3. Remove the ATF strainer (three bolts).
4. Remove the lower valve body assembly (six bolts) while pushing the connector out of the transmission housing.

5. Clean the inlet opening of the ATF strainer thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged.
6. Replace the ATF strainer if it is clogged or damaged.

NOTE: The ATF strainer can be reused if it is not clogged.

REAR COVER

Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the rear cover, replace the following:
- O-rings
- Mainshaft and countershaft locknuts
- Conical spring washers
- Rear cover gasket
- The washer on the rear cover is used on '96 models with the transmission No. M5HA - 1021049 and above, and on '97 -'98 models;'96 models with the transmission No. M5HA - 1000001 to M5HA - 1021048 do not use this part.

1. Remove the one bolt securing the ATF cooler lines to the transmission housing and the joint bolts, then remove the ATF cooler lines.
2. Remove the 34 x 1.25 mm sealing bolt and the washer from the rear cover, and the ten bolts securing the rear cover.

NOTE: The washer on the rear cover is used on '96 models with the transmission No. M5HA - 1021049 and above, and on '97 '98 models; '96 models with the transmission No. M5HA - 1000001 to M5HA -1021048 do not use this part.

3. Using snap ring pliers, expand the snap ring on the countershaft ball bearing and remove the rear cover.
4. Remove the two ATF feed pipes from the transmission housing.

5. Slip the special tool onto the mainshaft.
6. Engage the parking brake pawl with the parking gear.

7. Cut the lock tabs of each shaft locknut using a chisel as shown, then remove the locknuts from each shaft.

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

NOTE:
- Countershaft locknut has left-hand threads.
- Always wear safety glasses.

8. Remove the special tool from the mainshaft after removing the locknuts.
9. Remove the 24 mm washer, ball bearing, reverse gear, reverse gear distance collar and conical spring washer from the mainshaft.
10. Remove the 24 mm washer, ball bearing, 25 mm thrust washer, thrust needle bearing, reverse gear, thrust needle bearing, needle bearing, reverse gear collar, reverse clutch assembly, conical spring washer and reverse clutch distance collar from the countershaft.
11. Remove the 2nd clutch assembly from the mainshaft.
12. Remove the parking brake pawl shaft sleeve, pawl, spring, and shaft from the housing.
13. Remove the parking gear from the countershaft, and the 29 mm thrust washer, thrust needle bearing and 2nd gear from the mainshaft together.
14. Remove the thrust needle bearing, 45.5 x 60 mm thrust washer, needle bearings, 2nd gear one-way clutch and 2nd gear assembly from the countershaft.
15. Remove the needle bearing, thrust needle bearing and 2nd gear collar from the mainshaft.
16. Disconnect the connectors from the transmission sub-harness.

TRANSMISSION HOUSING

Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the transmission housing, replace the following:
- O-rings
- Transmission housing gasket

1. Remove the mainshaft and countershaft speed sensors from the transmission housing.
2. Remove the sixteen bolts securing the transmission housing with the transmission hanger, harness clamp bracket and speed sensor connector bracket.

3. Install the special tools on the transmission housing, then remove the transmission housing as shown.

CAUTION: Make sure that the mainshaft and countershaft speed sensors have been removed from the transmission housing before removing the transmission housing from the torque converter housing.

4. Remove the mainshaft sub-assembly and countershaft sub-assembly together.

NOTE: When removing the shafts, take care to prevent damage to the regulator valve body.

5. Remove the secondary driven gear shaft assembly.

TORQUE CONVERTER HOUSING/VALVE BODY

Removal

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the valve body from the torque converter housing, replace the O-ring.

1. Remove the eight 6 mm bolts and one 8 mm bolt securing the regulator valve body, then remove the regulator valve body.
2. Remove the stator shaft, stop shaft, and the regulator separator plate.
3. Remove the three 6 mm bolts and two 8 mm bolts securing the ATF pump body, then remove the ATF pump body.
4. Remove the ATF pump driven gear shaft, ATF pump gears, torque converter check valve, and spring.
5. Remove the four bolts securing the accumulator cover, then remove the accumulator cover.

NOTE: The accumulator cover is spring loaded. To prevent stripping the threads in the torque converter housing, press down on the accumulator cover while unscrewing the bolts in a crisscross pattern.

6. Remove the eight ATF feed pipes from the accumulator body.
7. Remove the eight 6 mm bolts and seven 6 mm special bolts securing the accumulator body, then remove the accumulator body.
8. Remove the torque converter housing separator plate with three dowel pins.

VALVE BODY
Repair

NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. You may use this procedure to free the valves in the valve bodies.

1. Soak a sheet of #600 abrasive paper in ATF for about 30 minutes.
2. Carefully tap the valve body so the sticking valve drops out of its bore.

CAUTION: It may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver.

3. Inspect the valve for any scuff marks. Use the ATF soaked #600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air.

4. Roll up half a sheet of ATF-soaked #600 paper and insert it in the valve bore of the sticking valve.
Twist the paper slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and out.

CAUTION: The valve body is aluminum and doesn't require much polishing to remove any burrs.

5. Remove the #600 paper. Thoroughly wash the entire valve body in solvent, then dry with compressed air.

6. Coat the valve with ATF, then drop it into its bore. It should drop to the bottom of the bore under its own weight. If not, repeat step 4, then retest. If the valve still sticks, replace the valve body.
7. Remove the valve, and thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF as a lubricant.

VALVE
Assembly

NOTE: Coat all parts with ATF before assembly.

- Install the valve, valve spring and cap in the valve body, and secure with the roller.

- Set the spring in the valve, then install them in the valve body. Push the spring in with a screwdriver, then install the spring seat.

- Install the valve, valve spring and cap in the valve body, then secure with the valve cap clip. Rotate the valve cap clip until it stops against the valve body wall.

VALVE CAPS
Description
- Caps with one projected tip and one flat end are installed with the flat end toward the inside of the valve body.

- Caps with a projected tip on each end are installed with the smaller tip toward the inside of the valve body. The small tip is a spring guide.

- Caps with one projected tip and a hollow end are installed with the tip toward the inside of the valve body. The tip is a spring guide.
- Caps with hollow ends are installed with the hollow end away from the inside of the valve body.
- Caps with notched ends are installed with the notch toward the inside of the valve body.

- Caps with flat ends and a hole through the center are installed with the smaller hole toward the inside of the valve body.

ATF PUMP
Inspection

1. Install the ATF pump gears and ATF pump driven gear shaft in the ATF pump body.

NOTE:
- Lubricate all parts with ATF during inspecting.
- Install the ATF pump driven gear with its grooved and chamfered side facing up as shown.

2. Measure the side clearance of the ATF pump drive and driven gears.

3. Remove the ATF pump driven gear shaft. Measure the thrust clearance of the ATF pump driven gear-to-valve body, with a straight edge and a feeler gauge.

SECONDARY VALVE BODY -'96 MODEL

Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF during assembly.
- Install the filters in the direction shown.

SECONDARY VALVE BODY -'97 -'98 MODELS

MAIN VALVE BODY -'96 MODEL
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF during assembly.
- Install the filters in the direction shown.

CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.

MAIN VALVE BODY -'97 -'98 MODELS
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF during assembly.
- Install the filters in the direction shown.

CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.

REGULATOR VALVE BODY -'96 MODEL
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fall to slide freely, see Valve Body Repair.

1. Hold the regulator spring cap in place while removing the stop bolt. The regulator spring cap is spring loaded. Once the stop bolt is removed, release the spring cap slowly so it does not pop out.
2. Reassembly is the reverse of the disassembly procedure.

NOTE:
- Coat all parts with ATF during assembly.
- Align the hole in the regulator spring cap with the hole in the valve body, press the spring cap into the body and tighten the stop bolt.

REGULATOR VALVE BODY -'97 -'98 MODELS
Disassembly/Inspection /Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fall to slide freely, see Valve Body Repair.

1. Hold the regulator spring cap in place while removing the stop bolt. The regulator spring cap is spring loaded. Once the stop bolt is removed, release the spring cap slowly so it does not pop out.
2. Reassembly is the reverse of the disassembly procedure.

NOTE:
- Coat all parts with ATF during assembly.
- Align the hole in the regulator spring cap with the hole in the valve body, press the spring cap into the body and tighten the stop bolt.

ACCUMULATOR BODY -'96 MODEL
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Coat all parts with ATF during assembly.

ACCUMULATOR BODY -'97 -'98 MODELS
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Coat all parts with ATF during assembly. e The 3rd accumulator and the 4th accumulator use the same size piston. The 3rd accumulator piston has the spring (3rd accumulator spring C) at its bottom.

ATF PUMP BODY -'96 MODEL
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF during assembly.
- Install the filter in the direction shown.

ATF PUMP BODY -'97 -'98 MODELS
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with ATF during assembly.
- Install the filter in the direction shown.

REVERSE ACCUMULATOR/ 1ST-HOLD ACCUMULATOR -'96 MODEL
Disassembly/Inspection /Reassembly

NOTE:
- Clean all parts thoroughly insolvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the O-rings.
- Coat all parts with ATF during assembly.

REVERSE ACCUMULATOR/1 ST-HOLD ACCUMULATOR -'97 -'98 MODELS
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the O-rings.
- Coat all parts with ATF during assembly.

ACCUMULATOR PISTON
Removal
1. Remove the snap ring.
2. Remove the accumulator sleeve and spring.
3. Remove the sealing bolt.
4. Remove the one-way ball spring ('96 model).

NOTE: Do not remove the steel ball.

5. Wrap a shop towel around the accumulator piston, and apply air pressure to the fluid passage to remove the piston.

WARNING:
- Do not place your fingers in front of piston.
- Do not use high air pressure; use an OSHA approved 30 PSI nozzle.

REAR COVER/CLUTCH FEED PIPES
Disassembly/Inspection/Reassembly

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace the O-rings.
- Coat all parts with ATF during assembly.