8. Transmission End Cover Installation
End Cover and Idler Gears InstallationSpecial Tools Required
Mainshaft holder 07GAB-PF50101 orO7GAB-PF50100
1. Install the park lever (A) and park lever stop (B) on the control shaft (C), then install the lock bolt (D) with a new lock washer (E). Do not bend the lock tab of the lock washer until step 25.
2. Lubricate the following parts with ATF:
- Splines of the countershaft, the park gear, and the old locknut.
- Threads of the countershaft and the old locknut.
- Old conical spring washer.
3. Install the park gear (A) using the old locknut (B) and a collar (C). Hold the park pawl (D) against the park gear, then tighten the old locknut until the shaft splines come out slightly over the park gear splines.
NOTE:
- Do not use an impact wrench.
- Countershaft locknut has left-hand threads.
4. Remove the locknut and the collar, then install only the bearing hub/bearing assembly (A) and old conical spring washer (B). Tighten the old locknut (C) to 226 Nm (23.0 kgf-cm, 166 ft. lbs.), then remove the locknut and conical spring washer.
NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.
5. Remove the bearing hub/bearing assembly (A) with a puller (B).
6. Install the thrust needle bearing (A), needle bearing (B), countershaft idler gear (C), thrust needle bearing (D), bearing hub/bearing assembly (E), and the old conical spring washer (F). Then tighten the old locknut (G) to 164 Nm (17.0 kgf-cm, 123 ft. lbs.).
NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.
7. Set the dial indicator (A) to the countershaft idler gear (B) as shown.
8. Measure the countershaft idler gear axial clearance in at least three places, while moving the countershaft idler gear. Use the average as the actual clearance.
9. If the clearance is out of standard, remove the bearing hub/bearing assembly using a puller as described on the previous page.
10. Select and install the new bearing hub/bearing assembly, then recheck.
11. After replacing the bearing hub/bearing assembly, make sure the clearance is within standard.
12. Remove the old locknut and old conical spring washer from the countershaft.
13. Install the special tool onto the mainshaft.
14. Lubricate the following parts with ATF:
- Splines of the mainshaft, secondary shaft, and idler gears.
- Threads of the mainshaft and secondary shaft.
- Threads of the old mainshaft and secondary shaft locknuts.
- Old conical spring washers.
15. Install the mainshaft idler gear (A) and the old conical spring washer (B) on the mainshaft (C). Tighten the old locknut (D) to 226 Nm (23.0 kgf-cm, 166 ft. lbs.)
NOTE: Use a torque wrench to tighten the locknut. Do not use an impact wrench.
16. Install the secondary shaft idler gear (E) and the old conical spring washer (F) on the secondary shaft (G). Tighten the old locknut (H) to seat the secondary shaft idler gear to 226 Nm (23.0 kgf-cm, 166 ft. lbs.)
NOTE:
- Use a torque wrench to tighten the locknut. Do not use an impact wrench.
- Secondary shafts locknut has left-hand threads.
17. Remove the old locknuts and old conical spring washers from the mainshaft and the secondary shaft.
18. Lubricate the threads of each shaft, the new locknuts, and the new conical spring washers with ATF.
19. Install the new conical spring washers (A) in the direction shown, and install the new locknuts (B).
20. Tighten the locknut to 167 Nm (17.0 kgf-cm, 123 ft. lbs.).
NOTE:
- Use a torque wrench to tighten the locknut. Do not use an impact wrench.
- Countershaft and secondary shaft locknuts have left-hand threads.
21. Stake each locknut into its shaft using a 3.5 mm munch.
22. Install the pitot flange (A) on the mainshaft idler gear (B), then install the lubrication pitot pipe (C) and the pitot pipe (D) on the transmission housing.
23. Set the park lever in the [1] position, then verify that the park pawl (A) engages the park gear (B).
24. If the park pawl does not engage fully, check the distance between the pawl shaft (C) and the park lever roller pin (D).
25. Tighten the lock bolt (E), and bend the lock tab of the lock washer (F) against the lock bolt head.
26. Install the end cover (A) with the two dowel pins, new O-rings, new gasket, and harness clamp bracket (B). Tighten the 16 bolts to 12 Nm, (1.2 kgf-cm, 8.7 ft. lbs.).
27. Set the A/T gear position switch to the N position.
NOTE: The A/T gear position switch clicks in the N position.
28. Set the control shaft (A) to the 0f position by turning it.
NOTE: Be careful not to squeeze the end of the control shaft tips together. If the tips are squeezed together it will cause a faulty signal or position due to the play between the control shaft and position switch.
29. Install the A/T gear position switch (A) gently on the control shaft (B), then secure it with the bolts. Take care not to move the A/T gear position switch when tightening the bolts.
30. Install the A/T gear position switch cover (c); install the harness clamp (D) on the clamp bracket (E); install the harness clamp (F) on the end cover (G).
31. Install the ATF cooler lines and new sealing washers. Tighten the line fittings to 28 Nm (2.9 kgf-cm, 21 ft. lbs.)
32. Install the breather tube.
33. Install the ATF dipstick.