Part 1
RIGHT SIDE COVER
Removal
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the transmission right side cover, replace the following:
- Right side cover gasket
- Lock washers
- O-rings
- Each shaft locknut
- Conical spring washers
- Sealing washers
1. Remove the 13 bolts securing the right side cover, then remove the right side cover.
2. Slip the special tool onto the mainshaft as shown.
3. Engage the parking brake pawl with the parking gear.
4. Align the hole of the sub-shaft 1st gear with the hole of the the transmission housing, then insert a pin to lock the sub-shaft while removing the sub-shaft locknut.
5. Cut the lock tabs of the each shaft locknut using a chisel as shown. Then remove the locknut from each shaft.
NOTE:
- Mainshaft and countershaft locknuts have left hand threads.
- Clean the old countershaft locknut, it is used to press the parking gear on the countershaft.
- Always wear safety glasses.
CAUTION: Keep all of the chiseled particles out of the transmission.
6. Remove the lock pin that was installed to hold the sub-shaft.
7. Remove the special tool from the mainshaft after removing the locknut.
8. Remove the 1st clutch and mainshaft 1st gear assembly from the mainshaft.
9. Remove the sub-shaft 1st gear.
10. Remove the parking brake pawl.
11. Using a universal two jaw puller, remove the parking gear, one-way clutch and countershaft 1st gear assembly.
12. Remove the parking brake lever from the control shaft.
13. Remove the throttle control drum from the throttle control shaft.
14. Remove the ATF cooler lines.
15. Remove the ATF dipstick.
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:
- Transmission housing gasket
- Lock washer
1. Remove the transmission mount bracket.
2. Remove the transmission housing mounting bolts and hanger.
3. Align the spring pin of the control shaft with the transmission housing groove by turning the control shaft.
4. Install the special tool on the transmission housing, then remove the housing as shown.
5. Remove the countershaft reverse gear with the collar and needle bearing.
6. Remove the lock bolt securing the shift fork, then remove the fork with the reverse selector from the countershaft.
7. Remove the countershaft and mainshaft sub assembly together.
8. Remove the differential 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 replace the following:
- O-rings
- Lock washers
1. Remove the ATF feed pipes from the servo body, servo detent base, accumulator cover, lock-up valve body and main valve body.
2. Remove the three bolts securing the ATF strainer and servo detent base, then remove the strainer and detent base.
3. Remove the three bolts securing the accumulator cover, then remove the accumulator cover.
4. Remove the six bolts securing the servo body, then remove the servo body and separator plate.
5. Remove the one bolt securing the secondary valve body, then remove the secondary valve body and separator plate.
6. Remove the eight bolts securing the lubricator plate and lock-up valve body, then remove the lubricator plate, lock-up valve body, and separator plate.
7. Remove the one bolt securing the regulator valve body, then remove the regulator valve body.
8. Remove the stator shaft and stop shaft.
9. Remove the detent spring from the detent arm, then remove the control shaft from the torque converter housing.
10. Remove the detent arm and detent arm shaft from the main valve body.
11. Remove the four bolts securing the main valve body, then remove the main valve body.
12. Remove the ATF pump driven gear shaft, then re move the ATF pump gears.
13. Remove the main separator plate with two dowel pins.
14. 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.
15. Replace the ATF strainer if it is clogged or damaged.
NOTE: The ATF strainer can be reused if it is not clogged.
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 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.
- Caps with flat ends and a, groove around the cap are installed with the grooved side toward the outside of the valve body.
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 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 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 and 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 and install them in the valve body.
Push the spring in with a screwdriver, then install the spring seat.
- Install the valve, spring and cap in the valve body. Push the cap, then install the clip.
ATF PUMP
Inspection
1. Install the ATF pump gears and ATF pump driven gear shaft in the main valve 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, and measure the thrust clearance of the ATF pump driven gear-to-main valve body.
MAIN VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace 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.
CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.
REGULATOR VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace 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.
1. Hold the regulator spring cap in place while removing the lock bolt. Once the bolt is removed, release the spring cap slowly.
CAUTION: The regulator spring cap can pop out when the lock bolt is removed.
2. Reassembly is in the reverse order of the disassembly procedure.
NOTE:
- Coat all parts with ATF.
- 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 lock bolt.
LOCK-UP VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace 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 before reassembly.
SECONDARY VALVE BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace 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 before reassembly.
CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.
SERVO BODY
Disassembly/Inspection/Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Replace valve body as an assembly if any parts are worn or damaged.
- Coat all parts with ATF before reassembly.
- Replace the O-rings.
1ST-HOLD ACCUMULATOR/RIGHT SIDE COVER
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 before reassembly.
MAINSHAFT
Disassembly/Inspection/Reassembly
NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
- Locknut has left-hand threads.
Inspection (Clearance Measurement)
NOTE: Lubricate all parts with ATF during assembly.
1. Remove the mainshaft bearing from the transmission housing.
2. Assemble the parts below on the mainshaft.
NOTE: Do not assemble the O-rings during inspection.
3. Torque the mainshaft locknut to 29 Nm (3.0 kgf.m, 22 ft. lbs.).
NOTE: Mainshaft locknut has left-hand threads.
4. Hold 2nd gear against the 2nd clutch, then measure the clearance between 2nd gear and 3rd gear with a feeler gauge.
NOTE: Take measurements in at least three places, and use the average as the actual clearance.
5. If the clearance is out of tolerance, remove the thrust washer and measure the thickness.
6. Select and install a new washer, then recheck.
7. After replacing the thrust washer, make sure the clearance is within tolerance.
COUNTERSHAFT
Disassembly/Inspection/Reassembly
NOTE:
- Lubricate all parts with ATF before reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
- Locknut has left-hand threads.
Disassembly/Reassembly
1. Using a hydraulic press, press out the countershaft while supporting 4th gear.
NOTE: Place an attachment between the press and the countershaft to prevent damage to the shaft.
CAUTION: Do not allow the countershaft to fall and hit the ground.
2. Assemble the parts on the countershaft as shown below.
NOTE:
- Lubricate all parts with ATF during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
3. Install the reverse selector hub on the countershaft sub-assembly, and then press the reverse selector hub using the special tool and a press as shown.
Inspection (Clearance Measurement)
NOTE: Lubricate all parts with ATF during assembly.
1. Remove the countershaft bearing from the transmission housing.
2. Install the parts below on the countershaft using the special tool and a press as described.
NOTE: Do not assemble the O-rings during inspection.
3. Install the parts below on the countershaft subassembly, then torque the locknut to 29 Nm (3.0 kgf.m, 22 ft. lbs.)
NOTE: countershaft locknut has left-hand threads.
4. Measure the clearance between the 2nd gear and the 28 mm distance collar with a feeler gauge.
NOTE: Take measurement in at least three places and use the average as the actual clearance.
5. If the clearance is out of tolerance, remove the 28 mm distance collar and measure the width.
6. Select and install a new distance collar, then recheck.
7. After replacing the distance collar, make sure the clearance is within tolerance.
ONE-WAY CLUTCH
Disassembly/Inspection/Reassembly
1. Separate countershaft 1st gear from the parking gear by turning the parking gear in the direction shown.
2. Remove the one-way clutch by prying it up with the end of a screwdriver.
3. After the parts are assembled, hold countershaft 1st gear and turn the parking gear in the direction shown to be sure it turns freely. Also make sure the parking gear does not turn in the opposite direction.
SUB-SHAFT
Disassembly/Inspection/Reassembly
NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
Disassembly/Reassembly
1. Remove the ATF guide cap by pushing the sub-shaft inside the transmission housing.
2. Remove the 1st-hold clutch assembly by pulling the sub-shaft, then remove the sub-shaft.
3. Install new O-rings on the sub-shaft.
NOTE: Wrap the shaft splines with tape to prevent damaging the O-rings.
4. Place the sub-shaft in the transmission housing and install the 1st-hold clutch assembly.
5. Install new ATF guide cap using the special tools as shown.
NOTE: Install the ATF guide cap in the direction shown.
SUB-SHAFT BEARINGS
Replacement
NOTE: Lubricate all parts with ATF before reassembly.
1. To remove the sub-shaft ball bearing from the transmission housing, expand the snap ring with snap ring pliers, then push the bearing out using the special tools and a press as shown.
2. Remove the needle bearing stopper.
3. Remove the needle bearing from the transmission housing using a drift punch.
4. Install the new needle bearing in the transmission housing using the special tools and a press as shown.
5. Expand the snap ring with snap ring pliers, then insert the ball bearing part-way into the housing using the special tools and a press as described in step 1. Install the bearing with the groove facing outside the housing.
6. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
7. After installing the ball bearing, verify the following:
- The snap ring is seated in the bearing and housing grooves.
- The snap ring operates properly.
- The ring end gap is correct.