Part 3
SECONDARY DRIVEN GEAR SHAFT
Components
Disassembly
1. Remove the set ring.
2. Remove the extension shaft from the secondary driven gear shaft.
Oil Seal Replacement
1. Remove the oil seal from the secondary driven gearshaft.
2. Drive the oil seal into the secondary driven gearshaft using the special tools as shown.
Tapered Roller Bearing Replacement
NOTE:
- The bearing and outer race should be replaced as a set.
- If the bearing is replaced, inspect and adjust the bearing preload.
1. Remove the tapered roller bearings from the secondary driven gear shaft using a bearing puller and separator as shown.
2. Install the bearings using the special tool and a press as shown.
NOTE: Press the bearings in squarely until they bottom.
Tapered Roller Bearing Outer Race Replacement
NOTE:
- Replace the bearing with a new one whenever the outer race is replaced.
- Adjust preload after replacing the bearing and outer race.
- Coat all parts with ATF during installation.
- The illustration shows '96 model; '97 - '98 models is similar.
1. Remove the bearing outer race from the transmission housing and torque converter housing by heating the housing to about 212°F (100°C).
CAUTION: Do not heat the housing in excess of 212°F (100°C).
2. Install the thrust shim and outer race in the transmission housing using the special tools as shown.
NOTE:
- Install the outer race squarely in the transmission housing.
- Check that there is no clearance between the outer race, thrust washer and transmission housing.
3. Install the 90 mm thrust washer and outer race in the torque converter housing using the special tools as shown.
NOTE:
- The 90 mm thrust washer is used on '96 models with the transmission No. M5HA - 1000001 to M5HA - 1014322; '96 models with the transmission No. M5HA - 1014323 and above, and '97 -'98 models do not use this part.
- Install the outer race squarely in the torque converter housing.
- Check that there is no clearance between the outer race, thrust washer, and torque converter housing.
Tapered Roller Bearing Preload Adjustment
NOTE:
- If the transmission housing, torque converter housing, secondary driven gear shaft, tapered roller bearing, outer race, thrust shim, or thrust washer were replaced, the bearing preload must be adjusted.
- The illustration shows '97 - '98 models; '96 model is similar.
- The 90 mm thrust washer is used on '96 models with the transmission No. IVI5HA - 1000001 to IV15HA -1014322; '96 models with the transmission No. WHA - 1014323 and above, and '97 -'98 models do not use this part.
1. Remove the oil seals from both housings.
2. Remove the bearing outer race and thrust shim from the transmission housing by heating the housing to about 212'F (100°C) with a heat gun.
CAUTION:
- Do not heat the housing in excess of 212°F (100°C).
- Replace the tapered roller bearing when the outer race is to be removed.
NOTE: Let the transmission housing cool to room temperature before adjusting the bearing preload.
3. Select the 1.98 mm (0.078 inch) thrust shim from the middle of the table below.
4. After installing the thrust shim, install the outer race in the transmission housing using the special tools.
NOTE:
- Install the outer race squarely in the transmission housing.
- Check that there is no clearance between the outer race, shim, and transmission housing.
5. Install the sealing bolt to the secondary driven gear shaft, and torque it to 20 Nm (2.0 kgfm, 14 ft. lbs.).
6. With the mainshaft and countershaft removed, install the secondary driven gear shaft, and torque the transmission housing.
NOTE: Install the gasket when checking starting torque.
7. Rotate the secondary driven gear shaft in both directions to seat the bearing.
8. Measure the starting torque of the secondary driven gear shaft with a torque wrench.
NOTE:
- Measure the starting torque at normal room temperature in both directions.
- Changing the shim to the next size will increase or decrease starting torque about 0.3 - 0.4 Nm (3 - 4 kgfcm, 3 - 4 inch lbs.).
- To increase the starting torque, increase the thickness of the shim. To decrease the starting torque, decrease the thickness of the shim.
OIL SEALS
Removal
1. Remove the oil seal from the transmission housing.
2. Remove the oil seal from the torque converter housing.
Installation
1. Install the oil seal in the transmission housing using the special tool as shown.
2. Install the oil seal into the torque converter housing using the special tools as shown.
3. Install the snap ring in the torque converter housing ('96 model).
NOTE: The snap ring is used on '96 models with the transmission No. M5HA - 1000001 to M5HA -1014322; '96 models with the transmission No. M5HA - 1014323 and above, and '97 - '98 models do not use this part.
TORQUE CONVERTER HOUSING BEARINGS
Mainshaft Bearing/Oil Seal Replacement
1. Drive out or pull up the mainshaft bearing and oil seal using the special tools as shown.
2. Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown.
3. Install the new oil seal flush with the housing using the special tools as shown.
Countershaft Bearing Replacement
1. Remove the countershaft roller bearing using the special tool as shown.
2. Install the ATF guide plate.
3. Drive the new bearing into the housing using the special tools as shown.
TRANSMISSION HOUSING MAINSHAFT BEARING
Replacement
1. To remove the mainshaft bearing from the transmission housing, expand the snap ring with the snap ring pliers, then push the bearing out.
NOTE: Do not remove the snap ring unless it's necessary to clean the groove in the housing.
2. Expand the snap ring with the snap ring pliers, insert the new bearing part-way into it, then release the pliers. Push the bearing down into the transmission until the ring snaps in place around it.
NOTE: Install with groove side of the bearing facing inside the transmission housing.
PARKING BRAKE MECHANISM
Disassembly/Inspection/Reassembly
1. Remove the parking brake pawl shaft sleeve, parking brake pawl and parking brake pawl spring.
2. Remove the A/T gear position switch.
3. Remove the bolt securing the detent lever to the control shaft, then remove the control shaft.
4. Remove the detent lever and parking brake rod assembly from the transmission housing.
5. Assemble the parking brake mechanism in the reverse order of disassembly.
A/T GEAR POSITION SWITCH
Removal
1. Shift the detent lever to the [P] position.
2. Pry the locktabs on the lock washer, then remove the locknut and lock washer.
3. Remove the bolts securing the A/T gear position switch, then remove the A/T gear position switch.
Installation
1. Set the A/T gear position switch to the FN] position as shown.
NOTE: The A/T gear position switch clicks in the
2. Shift the detent lever to the [N] position.
3. Install the A/T gear position switch on the control shaft, then install the bolts loosely.
4. Install a new lock washer on the A/T gear position switch by aligning its projected tip with the H position mark on the A/T gear position switch as shown.
5. Tighten the locknut while holding the detent [ever in the FY] position, then bend the lock tabs against the locknut.
6. Tighten the 6 mm bolts to the specified torque.
TRANSMISSION REASSEMBLY
NOTE:
- Coat all parts with ATF.
- Replace the following parts:
- O-rings
- Lock washers
- Gaskets
- Mainshaft and countershaft locknuts and conical disc springs
- Sealing washers
TORQUE:
- 6 x 1.0 mm Bolts: 12 Nm (1.2 kgfm, 8.7 ft. lbs.)
- 8 x 1.25 mm Bolts: 18 Nm (1.8 kgfm, 13 ft. lbs.)
1. Install the torque converter housing separator plate and three dowel pins on the torque converter housing.
2. Install the ATF pump drive gear, ATF pump driven gear, ATF driven gear shaft, torque converter check valve, and spring on the torque converter housing.
NOTE: Install the ATF pump driven gear with its grooved and chamfered side facing down.
3. Loosely install the ATF pump body with two 8 mm bolts and three 6 mm bolts. Make sure the ATF pump drive gear rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft moves smoothly in the axial and normal operating directions.
4. Install the accumulator body (eight bolts and seven special bolts).
5. Install the two dowel pins on the accumulator body, then install the accumulator cover while pressing it down (four bolts).
6. Tighten the bolts on the ATF pump body to the specified torque. Make sure the ATF drive gear and the ATF driven gear shaft move smoothly.
7. If the ATF pump drive gear and ATF driven gear shaft do not move freely, loosen the bolts on the ATF pump body, and remove the accumulator cover and accumulator body.
8. Realign the ATF pump driven gear shaft, reinstall the accumulator body and the accumulator cover, then retighten the bolts on the ATF pump body to the specified torque. Recheck the ATF drive gear and the ATF driven gear shaft movement.
CAUTION: Failure to align the ATF pump driven gear shaft correctly will result in seized ATF pump gears or a ATF pump driven gear shaft.
9. Install the regulator separator plate and two dowel pins on the ATF pump body.
10. Install the stator shaft with a new O-ring and stop shaft.
11. Install the regulator valve body (eight 6 mm bolts and one 8 mm bolt).
12. Install the ATF feed pipes on the accumulator body.
13. Install the parking brake rod assembly with the detent lever on the control shaft, and install the detent spring on the transmission housing, if necessary.
14. Assemble the mainshaft sub-assembly.
15. Assemble the countershaft sub-assembly.
16. Install the secondary driven gear shaft in the torque converter housing.
17. Install the mainshaft sub-assembly and the countershaft sub-assembly together in the torque converter housing.
NOTE: Take care to prevent damage to the regulator valve body, when installing the shafts.
18. Install the two dowel pins and a new gasket on the torque converter housing.
19. Place the transmission housing on the torque converter housing.
CAUTION: Make sure that the mainshaft and countershaft speed sensors are not installed on the transmission housing before installing the transmission housing on the torque converter housing.
20. Install the transmission housing mounting bolts with the transmission hanger, harness clamp bracket, and speed sensor connector bracket, then tighten them in two or more steps in the sequence shown.
21. Install the mainshaft and countershaft speed sensors with the washers on the transmission housing.
22. Install the countershaft 2nd gear assembly, 2nd gear one-way clutch, needle bearings, thrust washer, and thrust needle bearing on the countershaft.
23. Install the 2nd gear collar, thrust needle bearing, and needle bearing on the mainshaft.
24. Combine the mainshaft 2nd gear with the parking gear, then install them on their respective shafts.
25. Tap the parking gear very lightly to install in the 2nd gear one-way clutch, using the special tool as shown.
26. Install the parking brake pawl shaft, spring, pawl, and sleeve in the transmission housing.
27. Install the ATF feed pipe in the accumulator cover.
28. Install the reverse clutch distance collar and a new countershaft conical spring washer on the countershaft.
NOTE: Install the conical spring washers in the direction shown.
29. Install the thrust needle bearing and 29 mm thrust washer on the mainshaft.
30. Install new O-rings on the countershaft and main shaft.
NOTE: Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
31. Install the 2nd clutch assembly on the mainshaft, then install the reverse clutch assembly, reverse gear collar, needle bearing, thrust needle bearing, reverse gear, thrust needle bearing, 25 mm thrust washer and ball bearing on the countershaft.
32. Install a new mainshaft conical spring washer, reverse gear distance collar, reverse gear and ball bearing on the mainshaft.
33. Install the special tool onto the mainshaft as shown.
34. Engage the parking brake pawl with the parking gear by moving the detent lever to the [P] position.
35. Coat the 24 mm washers with ATF, then install them and new locknuts on each shaft.
36. Tighten the locknuts to the specified torque using a torque wrench.
TORQUE: 127 Nm 113.0 kgfm, 94 ft. lbs.)
NOTE: Countershaft locknut has left-hand threads.
37. Stake each locknut into its shaft, using a 3.5 mm (0.14 inch) punch as shown.
38. Install two dowel pins, four ATF feed pipes with new O-rings, and a new rear cover gasket on the transmission housing.
39. Install the rear cover and engage the reverse gears while rotating the mainshaft.
40. Push the rear cover with expanding the snap ring with the snap ring pliers until the ring snaps in place around the bearing.
NOTE: Make sure the snap ring fits in place around the bearing. If not, raise the countershaft to fit the
41. Tighten the bolts on the rear cover (ten bolts).
TORQUE: 26 Nm (2.7 kgfm, 20 ft. lbs.)
42. Apply liquid gasket (P/N 08718 - 0001) to the sealing bolt threads, and install the washer and the sealing bolt on 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 have this part.
TORQUE:
78 Nm (8.0 kgfm, 58 ft. lbs.): '96 models with transmission No. M51HIA - 1000001 to M51HIA - 1021048
98 Nm (110.0 kgfm, 72.3 ft. lbs.): '96 models with transmission No. M51HIA - 1021049 and above, and '97 -'98 models Transmission No. M51HIA - 2000001 -)
43. Assemble the lower valve body assembly.
44. Pass the shift control solenoid valve/linear solenoid harness through the transmission housing, and put the manual valve and the detent lever together. Then install the lower valve body assembly (six bolts) with two dowel pins in the transmission housing.
45. Install the ATF strainer (three bolts).
46. Position the connector stop on the shift control solenoid valve/linear solenoid harness connector groove, then tighten the bolt.
47. Install the ATF pan with two dowel pins and a new gasket (fourteen bolts).
48. Install the ATF cooler lines with new sealing washers, then tighten the joint bolts.
49. Connect the transmission sub-harness connector to speed sensor connectors and solenoid connectors.