Acura 2.5TL 3.2TL 1995 -1998 Service Manual_Part6

Lower Valve Body Assembly

Disassembly

NOTE:Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.Blow out all passages.Do not let the check balls fall out of the main valve body when removing the main valve body.Replace the filters.

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

SHIFT CONTROLSOLENOID VALVEASSEMBLY

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

SERVO BODY

DOWEL PIN

MAIN SEPARATORPLATE

6 x 1.0 mm12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

SHIFT FORK

SERVO DETENT BASE

ATF FEED PIPE

LOCK WASHERReplace.

6 x 1.0 mm14 N-m(1.4 kgf-m, 10 Ibf-ft)

ATF PASS BODY

ATF FEED PIPES

MAIN VALVE BODY

MAIN VALVE BODY COVER

6 x 1.0 mm12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

SHIFT CONTROL SOLENOIDVALVE HARNESS

CHECK BALLS

FILTERSReplace.

Reassembly

NOTE: Coat all parts with ATF. Replace the filters. Install the filters in the direction shown.

1. Install the main separator plate and the two dowelpins on the main valve body.

NOTE: Refer to page 14-141, when installing the checkballs on the main valve body.

2. Install the servo body on the main valve body (twobolts).

3. Install the main valve body cover on the main valvebody (six bolts) as shown.

4. Install the one bolt on the main valve body as shown.

5. Install the ATF feed pipes and ATF pass body.

Shift Fork

Installation

1. Turn the shift fork shaft so the large chamfered hole isfacing the fork bolt hole.

2. Install the shift fork and the lock bolt with a new lockwasher, and torque the bolt.

3. Bend the lock tab against the bolt head.

Parking Brake Roller Rod Detent Spring

Inspection

1. Shift to position.

2. Measure the clearance between the transmissionhousing and the tip of the parking brake roller rod asshown.

STANDARD: 3.8 - 4.3 mm (0.15 - 0.17 in)

3. If the clearance is out of tolerance, replace the park-ing brake roller rod.

NOTE: If the parking brake roller rod replacement isrequired, see Control Shaft/Detent Spring Reassembly(see page 14-176).

Measuring clearance

DETENT SPRING PARKING BRAKEROLLER ROD

Replacement

1. Shift to any gear other than the position.

CAUTION: Do not tighten the bolts when the detentlever is in the position; the parking brake rollerguide may be damaged.

2. Install the parking brake roller guide with two dowelpins, then torque the bolt.

3. Install a new detent spring, the detent spring plateand a new lock washer, then torque the bolts.

4. Bend the lock tab against the bolt heads.

DETENT SPRING

DETENT SPRINGPLATE

DOWEL PINS

PARKING BRAKEROLLER GUIDE

8 x 1.25 mm29 N-m(3.0 kgf-m, 22 Ibf-ft)

LOCK WASHERReplace.

8 x 1.25 mm29 N-m(3.0 kgf-m, 22 Ibf-ft)

Shift Control Solenoid Valve

Replacement

1. Remove the lower valve body assembly (see page14-108).

2. Remove the shift control solenoid valve assemblyfrom the servo body.

NOTE: Be sure to remove or replace the shift con-trol solenoid valves A and B as an assembly.

3. Check the shift control solenoid valve fluid pas-sages for dust or dirt. If necessary, replace as anassembly.

4. Clean the mounting surface and fluid passages ofthe shift control solenoid valve assembly, and installa new shift control solenoid valve assembly andnew filters.

SHIFT CONTROLSOLENOID VALVEASSEMBLY

6 x 1.0 mm12 N-m(1.2 kgf-m, 8.7 Ibf-ft)

LOWER VALVEBODY ASSEMBLY

SHIFT CONTROLSOLENOID VALVESEPARATOR PLATE

SHIFT CONTROLSOLENOID VALVEHARNESS

Lower Valve Body Assembly

Installation

NOTE:Coat all parts with ATF.Replace the O-rings and ATF pan gasket.

1. Shift the transmission into the position.

2. Assemble the lower valve body assembly (see page14-110 and 14-111).

3. Install the two dowel pins on the lower valve bodyassembly.

4. Push the shift fork in the D range position.

5. Install the lower valve body putting the manualvalve and the detent lever together, the reverseselector and the shift fork together, and joining theATF feed pipes with the ATF feed pipe holes on thetransmission housing.

6. Install the six bolts and torque as shown.2P CONNECTOR

O-RINGReplace.

DOWEL PINS

SHIFT FORK

SHIFT CONTROLSOLENOID VALVEHARNESSCONNECTOR Push shift forkin this direction.

LOWER VALVEBODY ASSEMBLY

TORQUE: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)6 x 25 mm

6 x 50 mm

6 x 50 mm 6 x 40 mm

7. Install the main valve body plate (four bolts).

8. Pass the shift control solenoid valve harness throughthe transmission housing, and install the shift controlsolenoid valve harness connector (one bolt).

9. Install the harness cover (four bolts).

10. Lightly pull the shift control solenoid valve harnessfrom the harness cover, then bring the shift controlsolenoid valve harness back. Make sure that the shiftcontrol solenoid valve harness is not pinched. If theshift control solenoid valve harness is pinched,loosen the four bolts securing the harness cover thenretighten the bolts.

TORQUE: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

6 x 20 mm

6 x 50 mm

6 x 16 mm8 N-m(0.8 kgf-m,6 Ibf-ft)

SHIFT CONTROL SOLENOIDVALVE HARNESS

HARNESS COVER

6 x 40 mm

6 x 40 mm MAIN VALVEBODY PLATE

6 x 50 mm

11. Install the ATF strainer with a new O-ring (four bolts).


6 x 50 mm

ATF STRAINER

6 x 45 mm

6 x 50 mm6 x 40 mm

12. Install the ATF pan with two dowel pins and a newATF pan gasket (fifteen bolts) as shown.Make sure that the shift control solenoid valve har-ness is not pinched by the ATF pan.


6 x 30 mm

6 x 30 mm

13.

ATF PAN

Install the A/T gear position switch cover. Tighten thebolt on the ATF pan side loosely so that there is noclearance between the A/T gear position switch coverand the ATF pan. Then tighten the bolt on the rearcover side to the specified torque, and tighten the bolton the ATF pan side to the specified torque.

6 x 1.0 mm(Rear cover side)12 N-m (1.2 kgf-m,8.7 Ibf-ft)

ATF PAN

A/T GEAR POSITIONSWITCH COVER 6 x 1.0 mm(ATF pan side)

12 N-m (1.2 kgf-m,8.7 Ibf-ft)

14. Connect the shift control solenoid valve connector.

15. Install the transmission mount bracket and trans-mission mount.

12 x 1.25 mm54 N-m (5.5 kgf-m,40 Ibf-ft) INSULATORS

TRANSMISSIONMOUNT BRACKET

12 x 1.25 mm54 N-m(5.5 Kgf-m,40 Ibf-ft)

MOUNTSTOPPER

WASHER

TRANSMISSIONMOUNT 12 x 1.25 mm

64 N-m (6.5 kgf-m,47 Ibf-ft)Replace.

16. Refill the transmission with ATF (see page 14-105).

17. Start the engine, and shift the transmission throughall gears three times. Check the shift lever operationand the A/T gear position indicator operation.

18. Let the engine reach operating temperature (the radi-ator fan comes on) with the transmission in the orE position, then turn it off and check ATF level.

Transmission

Removal

Make sure lifts are placed properly, andhoist brackets are attached to the correct position onthe engine (see section 1).

CAUTION: Use fender covers to avoid damaging paintedsurfaces.

1. Before disconnecting power, make sure you havethe anti-theft code for the radio, then write downthe frequencies for the radio's preset buttons.

2. Disconnect the battery negative (-) terminal fromthe battery, then remove the positive (+) terminal.

3. Remove the battery hold-down bracket and battery.

4. Disconnect the ignition coil wire connector, andremove it and the engine ground cable from the heatshield cover.

IGNITION COILWIRE CONNECTOR HEAT SHIELD

COVER

ENGINEGROUNDCABLE

5. Remove the upper heat shield cover, then remove thebattery base.

6. Loosen the lower heat shield cover bolts, then removethe lower heat shield cover.

BATTERYBASE

UPPER HEATSHIELD COVER

LOWER HEATSHIELD COVER

7. Disconnect the connector from the control box, andremove the control box.

CAUTION: Do not disconnect the vacuum hoses fromthe control box.

CONTROL BOX

CONTROL BOX CONNECTOR

8. Remove the torque converter cover.

9. Remove the eight drive plate bolts one at a time whilerotating the crankshaft pulley.

NOTE: If necessary, remove the spark plugs whileremoving the drive plate bolts.

DRIVE PLATE/RING GEAR

DRIVE PLATEBOLT

TORQUE CONVERTERCOVER

10. Remove the transmission sub-harness connector.

11. Remove the transmission ground cable.

12. Remove the transmission housing mounting boltsand the 26 mm shim.

TRANSMISSIONGROUND CABLE

TRANSMISSION HOUSINGMOUNTING BOLTS

TRANSMISSION HOUSINGMOUNTING BOLTS

TRANSMISSIONSUB-HARNESSCONNECTOR

26 mm SHIM

13. Remove the drain plug, and drain the automatictransmission fluid (ATF). Reinstall the drain plug witha new sealing washer.

TORQUE: 49 N-m (5.0 kgf-m, 36 Ibf-ft)

DRAIN PLUG1.8 x 1.5 mm

SEALING WASHERReplace.

14. Remove the transmission mount and mount bracket.

15. Remove the ATF cooler hoses at the joint pipes.Turn the ends of the cooler hoses up to prevent ATFfrom flowing out, then plug the joint pipes.

JOINTPIPES

ATF COOLERHOSES


TRANSMISSIONMOUNT

Transmission

Removal (cont'd)

16. Shift the transmission into the position.

17. Remove the 33 mm sealing bolt.

18. Remove the extension shaft from the differential usingthe special tool as shown.

33 mmSEALING BOLT

EXTENSION SHAFT

EXTENSION SHAFTPULLER07LAC-PW50101

19. Remove the two bolts from the exhaust pipe A stay.

20. Remove the exhaust pipe A and exhaust manifoldbrackets.

GASKETReplace.

EXHAUST MANIFOLDBRACKETS

EXHAUSTPIPE A

GASKETReplace.

21. Remove the shift cable cover.

22. Remove the shift cable holder from the transmissionrear cover.

23. Remove the control lever from the control shaft, thenremove the shift cable.

CAUTION: Take care not to bend the shift cable.

SHIFT CABLEHOLDER SHIFT CABLE

COVER BRACKETSHIFT CABLE COVER

FLOATINGWASHERS

LOCK WASHERReplace.

CONTROL SHAFT

CONTROL LEVER

24. Disconnect the A/T gear position switch connector,then remove the harness bracket.

HARNESS BRACKETA/T GEAR POSITIONSWITCH CONNECTOR

25. Remove the transmission mid mount nuts.

26. Place a jack under the transmission and raise thetransmission just enough to take weight off of themounts, then remove the mid mounts and mid mountspacer as shown.

TRANSMISSION

TRANSMISSIONMID MOUNTNUT

MID MOUNTSPACER

MID MOUNT

MID MOUNTS

OFFSET WRENCH(Commercially available)

27. Remove the transmission housing mounting bolts.

28. Remove the torque converter cover mounting bolt onthe torque converter housing side.

NOTE: Do not remove the torque converter covermounting bolt on the differential carrier side and thetorque converter cover.

TRANSMISSIONHOUSINGMOUNTINGBOLT

DOWEL PIN

TORQUE CONVERTERCOVERDo not remove.

Do not removethis bolt. TRANSMISSION HOUSING

MOUNTING BOLT

TORQUE CONVERTER COVERMOUNTING BOLTRemove this bolt.

29. Pull the transmission away from the engine until itclears the dowel pins, then lower it on the transmis-sion jack.

Illustrated Index

Transmission Housing/Lower Valve Body

A/T GEAR POSITION SWITCH COVERTRANSMISSION ATF PANDRAIN PLUGSEALING WASHER Replace.ATF PAN GASKET Replace.DOWEL PINSATF STRAINERMAIN VALVE BODY PLATEATF FEED PIPESATF PASS BODYATF FEED PIPESCHECK BALLSSERVO DETENT BASELOCK WASHER Replace.LOCK WASHER Replace.SHIFT FORKSHIFT CONTROL SOLENOID SEPARATOR PLATESHIFT CONTROL SOLENOID VALVE ASSEMBLYSHIFT CONTROL SOLENOID VALVE HARNESSCOVERMAIN VALVE BODY COVERMAIN VALVE BODYMAIN SEPARATOR PLATEDOWEL PINSDOWEL PINS

SERVO BODYFILTERS Replace.LOCK WASHER Replace.DETENT LEVERLOCK WASHER Replace.PARKING BRAKE STOPPERSHIFT ARM ROLLERPARKING BRAKE SHIFT ARMPARKING BRAKE ROLLER ROD Selective partPARKING BRAKE SHIFT ARM SPRINGCONTROL SHAFT COLLARLOCK WASHER Replace.LOCK WASHER Replace.DETENT SPRING PLATEDETENT SPRINGPARKING BRAKE ROLLER GUIDECONTROL SHAFTDOWEL PINSSHIFT CONTROL SOLENOID VALVE HARNESSCONNECTORO-RING Replace.MAINSHAFT SPEED SENSORCOUNTERSHAFT SPEED SENSORO-RINGS Replace.A/T GEAR POSITION SWITCHWASHER (M1WA-2015787-)

TORQUE SPECIFICATIONS

Illustrated Index

Rear Cover

REAR COVER1ST CLUTCH FEED PIPEO-RINGS Replace.FEED PIPE GUIDEBALL BEARINGSNAP RINGREAR COVER GASKET Replace.DOWEL PIN1ST-HOLD CLUTCH FEED PIPEO-RINGS Replace.FEED PIPE GUIDESNAP RINGATF FEED PIPESMAINSHAFT LOCKNUT, 24 x 1.25 mm (Flange nut) Replace.CONICAL SPRING WASHER Replace.1ST CLUTCH ASSEMBLYO-RINGS Replace.THRUST WASHERTHRUST NEEDLE BEARINGNEEDLE BEARINGMAINSHAFT 1ST GEARTHRUST WASHERMAINSHAFT 1ST GEAR COLLARCOUNTERSHAFT LOCKNUT, 24 x 1.25 mm (Flange nut) Replace.CONICAL SPRING WASHER Replace.1ST-HOLD CLUTCH ASSEMBLYO-RINGS Replace.THRUST WASHERTHRUST NEEDLE BEARING1ST-HOLD CLUTCH HUBCOUNTERSHAFT 1ST GEARONE-WAY CLUTCHNEEDLE BEARINGSCOUNTERSHAFT 1ST GEAR COLLARPARKING GEARPARKING BRAKE PAWL SHAFTPARKING BRAKE PAWL SPRINGPARKING BRAKE PAWLPARKING BRAKE PAWL STOPPERA/T GEAR POSITION SWITCH HARNESSATF DIPSTICK


Illustrated Index

Transmission Housing

SNAP RINGTHRUST WASHERTHRUST NEEDLE BEARINGMAINSHAFT 4TH/REVERSE GEARNEEDLE BEARINGSMAINSHAFT 4TH GEAR COLLARTHRUST NEEDLE BEARINGTHRUST WASHER4TH/2ND CLUTCH ASSEMBLYO-RINGS Replace.2ND GEAR THRUST WASHER, 37.5 x 56 mmSelective partTHRUST NEEDLE BEARINGMAINSHAFT 2ND GEARNEEDLE BEARINGSTHRUST NEEDLE BEARINGMAINSHAFTSEALING RINGS, 35 mmSEALING RING, 29 mmNEEDLE BEARINGSET RINGCOUNTERSHAFT REVERSE GEAR COLLARNEEDLE BEARINGCOUNTERSHAFT REVERSE GEARREVERSE SELECTORREVERSE SELECTOR HUBCOUNTERSHAFT 4TH GEARNEEDLE BEARINGDISTANCE COLLAR, 35 mm Selective partCOUNTERSHAFT 2ND GEARNEEDLE BEARINGCOUNTERSHAFT 3RD GEARNEEDLE BEARINGTHRUST NEEDLE BEARINGCOUNTERSHAFT 3RD GEAR COLLAR3RD CLUTCH ASSEMBLYO-RINGS Replace.

COUNTERSHAFTREVERSE IDLER GEAR SHAFT HOLDERO-RING Replace.REVERSE IDLER GEAR SHAFTNEEDLE BEARINGO-RING Replace.CONNECTOR HOLDERCOUNTERSHAFT SPEED SENSORMAINSHAFT SPEED SENSORO-RING Replace.LUBRICATION PIPESET RING Replace.TAPERED ROLLER BEARINGSECONDARY DRIVEN GEAR SHAFTTAPERED ROLLER BEARINGSECONDARY DRIVEN GEAR SHAFT OIL SEALReplace.EXTENSION SHAFTTHRUST SHIM, 68 mm Selective partTAPERED ROLLER BEARING OUTER RACESNAP RINGSTRANSMISSION HOUSING COUNTERSHAFTBEARINGTRANSMISSION HOUSING MAINSHAFT BEARINGDOWEL PINTRANSMISSION HOUSING GASKET Replace.REVERSE IDLER GEARTAPERED ROLLER BEARING OUTER RACETORQUE CONVERTER HOUSINGTORQUE CONVERTER HOUSING OIL SEAL Replace.SNAP RINGWASHER (used from transmission numberM1WA-3010520)


Illustrated Index

Torque Converter Housing/Valve Body

REGULATOR VALVE BODYO-RING Replace.STATOR SHAFTSTOPPER SHAFTREGULATOR SEPARATOR PLATEDOWEL PINATF FEED PIPEFILTER Replace.FILTER Replace.ATF PUMP BODYATF PUMP DRIVE GEARATF PUMP DRIVEN GEARATF PUMP DRIVEN GEAR SHAFTATF PUMP BODY SEPARATOR PLATEDOWEL PINTORQUE CONVERTER CHECK VALVETORQUE CONVERTER CHECK VALVE SPRING2ND ACCUMULATOR BODYATF FEED PIPESFILTER Replace.2ND ACCUMULATOR SPRINGO-RING Replace.2ND ACCUMULATOR PISTONO-RING Replace.DOWEL PINTHROTTLE VALVE BODY SEPARATOR PLATETHROTTLE VALVE BODY/LINEAR SOLENOID ASSEMBLYHARNESS CLAMPTORQUE CONVERTER HOUSING COUNTERSHAFT ROLLER BEARINGATF GUIDE PLATEATF FEED PIPESTORQUE CONVERTER HOUSINGTORQUE CONVERTER HOUSING MAINSHAFT BALL BEARINGOIL SEAL Replace.CONNECTOR BRACKETSTRANSMISSION SUB-HARNESSO-RING Replace.ATF DIPSTICK PIPEJOINT BOLTSEALING WASHER Replace.ATF COOLER PIPESEALING WASHER Replace.LINEAR SOLENOID HARNESSFLANGE NUT, 5 x 0.8 mm


Transmission Housing/Lower Valve Body Assembly

Removal

NOTE:Clean all parts thoroughly in solvent or carburetorcleaner, and dry with compressed air.Blow out all passages.When removing the lower valve body, replace the fol-lowing:

O-ringsATF pan gasket

CAUTION: Do not turn over the transmission beforeremoving the ATF pan.

1. Remove the shift control solenoid valve connectorfrom the connector holder, then separate it.

2. Remove the A/T gear position switch cover, thenremove the ATF pan.

ATF PANGASKETReplace.

AFT PAN

A/T GEAR POSITIONSWITCH COVER

DOWEL PINS

DETENT LEVER

SHIFT CONTROLSOLENOIDVALVE CONNECTOR

LOWER VALVEASSEMBLY

MAIN VALVEBODY PLATE

SHIFT CONTROL SOLENOIDVALVE HARNESS CONNECTOR

O-RINGReplace.

ATF STRAINER

O-RINGReplace.

3. Remove the ATF strainer (four bolts).

6 x 50 mm

6 x 45 mm

6 x 50 mm6 x 40 mm

4. Move the detent lever to the position.

NOTE: If the detent lever is not in the position,the lower valve body assembly cannot be removed.

5. Move the shift fork toward the torque converter sideas shown.

SHIFT FORK

6. Remove the main valve body plate (four bolts).

7. Remove the harness cover (four bolts).

8. Remove the one bolt securing the shift controlsolenoid valve harness connector, then remove theconnector and pull the harness out.

9. Remove the lower valve body assembly (six bolts).

NOTE: Refer to page 14-110; Lower Valve BodyAssembly Disassembly, when disassembling thelower valve body.

6 x 25 mm

6 x 40 mm

6 x 50 mm

6 x 16 mm

6 x 40 mm

6 x 50 mm

10. Clean the inlet opening of the ATF strainer thor-oughly with compressed air, then check that it is ingood condition, and the inlet opening is not clogged.

ATF STRAINER

INLET OPENING

11. Replace the ATF strainer if it is clogged or damaged.

NOTE: The ATF strainer can be reused if it is notclogged.

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-ringsMainshaft and countershaft locknutsConical spring washers

LOCKNUTSReplace.Mainshaft locknut has left-hand threads.

CONICAL SPRINGWASHERReplace.

1ST-HOLD CLUTCHASSEMBLY

THRUST WASHERTHRUST NEEDLEBEARING

1 ST-HOLD CLUTCHHUB

1ST GEAR

ONE-WAY CLUTCH

NEEDLE BEARINGS

1ST GEAR COLLAR

PARKING GEAR

COUNTERSHAFT

MAINSHAFT


1ST CLUTCHASSEMBLY

THRUST WASHER

THRUST NEEDLEBEARINGNEEDLE BEARING

1ST GEAR

THRUST WASHER

1ST GEAR COLLAR

6 x 1.0 mm Bolt8 Bolts

REAR COVER

DOWEL PINS

REAR COVERGASKETReplace.

ATF FEED PIPES, 4

A/T GEAR POSITIONSWITCH HARNESS

6 x 1.0 mm Bolt

1. Remove the one bolt securing the A/T gear positionswitch harness clamp.

2. Remove the eight bolts securing the rear cover, thenremove the rear cover.

3. Remove the four ATF feed pipes from the transmis-sion housing.

4. Slip the special tool onto the mainshaft.

MAINSHAFT HOLDER07GAB-PF50100 or07GAB-PF50101

5. Engage the parking brake pawl with the parking gear.

6. Cut the lock tabs of each shaft locknut using a chiselas shown. Then remove the locknuts and conicalspring washers from each shaft.

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

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

7. Remove the special tool from the mainshaft afterremoving the locknuts.

8. Remove the 1st-hold clutch assembly, thrust washer,thrust needle bearing and 1st-hold clutch hub fromthe countershaft.

9. Remove the 1st clutch assembly, thrust washer, thrustneedle bearing and 1st gear from the mainshaft.

10. Remove the 1st gear, one-way clutch, needle bear-ings, 1st gear collar and parking gear from the coun-tershaft.

11. Remove the thrust washer and 1st gear collar fromthe mainshaft.

12. Remove the parking brake pawl, shaft, spring, andstopper from the transmission housing.

LOCK TAB

CHISEL

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-ringsTransmission housing gasket

TRANSMISSION HOUSING

TRANSMISSION HOUSINGMOUNTING BOLTS10 x 1.25 mm10 Bolts

COUNTERSHAFT SPEEDSENSOR

MAINSHAFT SPEEDSENSOR

TRANSMISSIONHOUSING GASKETReplace.

COUNTERSHAFTSUB-ASSEMBLY

MAINSHAFTSUB-ASSEMBLY

SECONDARY DRIVENGEAR/SHAFT

TRANSMISSION HOUSINGMOUNTING BOLTS8 x 1.25 mm3 Bolts

EXTENSION SHAFT

CONNECTOR BRACKETS

TORQUE CONVERTERHOUSING

TRANSMISSION HOUSINGMOUNTING BOLT10 x 1.25 mm

DOWEL PINS, 3

WASHER (M1WA-3010520~)

CONNECTOR HOLDER

1. Disconnect the mainshaft and countershaft speedsensor connectors.

2. Remove the connector holder and connector brackets.

3. Remove the countershaft speed sensor and main-shaft speed sensor from the transmission housing.

4. Remove the ten bolts securing the transmission hous-ing, then remove the 10 mm bolt and three 8 mmbolts securing the transmission housing to thetorque converter housing side.

5. Install the special tool on the transmission housing,then remove the transmission housing as shown.

CAUTION: Make sure that the mainshaft and coun-tershaft speed sensors have been removed from thetransmission housing before removing the trans-mission housing from the torque converter housing.

HOUSING PULLER07HAC-PK4010A

TRANSMISSIONHOUSING

6. Remove the mainshaft sub-assembly and counter-shaft sub-assembly together.

NOTE: When removing the shafts, take care to pre-vent damage to the regulator valve body.



7. Remove the secondary driven gear shaft from thetorque converter housing.

Torque Converter Housing/Valve Body

RemovalNOTE:

Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.Blow out all passages.When removing the valve bodies, replace the following:

O-ringsFilters

2ND ACCUMULATORBODY

ATF FEED PIPE

THROTTLEVALVE BODYSEPARATORPLATE

2ND ACCUMULATORSPRING

2ND ACCUMULATORPISTON

ATF FEED PIPES

6 x 1.0 mm BOLTS9 Bolts

REGULATOR VALVE BODY

STATOR SHAFT

STOPPER SHAFT

REGULATORSEPARATOR PLATE

ATF PUMP BODY

ATF FEED PIPES



ATF PUMP DRIVE GEAR

ATF PUMP DRIVEN GEAR

TORQUE CONVERTERCHECK VALVETORQUE CONVERTERCHECK VALVE SPRING

ATF PUMP BODYSEPARATOR PLATE

ATF PUMP DRIVEN GEAR SHAFT

LOCK-UP CONTROLSOLENOID VALVECONNECTOR

LINEAR SOLENOIDCONNECTOR

TORQUE CONVERTERHOUSING LINEAR SOLENOID

HARNESS CONNECTOR

LINEAR SOLENOIDHARNESS

HARNESSCLAMP

THROTTLE VALVEBODY/LINEARSOLENOID ASSEMBLY

FLANGE NUTS

1. Remove the ATF feed pipe from the ATF pumpbody and two ATF feed pipes from the torque con-verter housing.

2. Remove the two flange nuts securing the linearsolenoid harness, then disconnect the harness fromthe linear solenoid and harness clamp.

3. Remove the regulator valve body (nine bolts).

4. Remove the stopper shaft and stator shaft.

5. Remove the regulator separator plate with two dowelpins.

6. Remove the six bolts securing the 2nd accumulatorbody, then remove the 2nd accumulator body andthrottle valve body/linear solenoid as an assembly.

7. Remove the ATF pump body (five bolts).

8. Remove the ATF pump gears and ATF pump drivengear shaft.

9. Remove the torque converter check valve and spring.

10. Remove the ATF pump body separator plate withthree dowel pins.

11. Remove the one bolt securing the linear solenoidharness connector, then remove the linear solenoidharness from the torque converter housing.

12. Disconnect the lock-up control solenoid valve con-nector, then remove the transmission sub-harness.

Valve Body

Repair

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

1. Soak a sheet of #600 abrasive paper in ATF forabout 30 minutes.

2. Carefully tap the valve body so the sticking valvedrops out of its bore.

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

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

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

CAUTION: The valve body is aluminum and doesn'trequire much polishing to remove any burrs.

ATF-soaked#600 abrasivepaper

5.

6.

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

Coat the valve with ATF, then drop it into its bore. Itshould drop to the bottom of the bore under its ownweight. If not, repeat step 4, then retest.

VALVE

VALVEBODY

7. Remove the valve, and thoroughly clean it and thevalve body with solvent. Dry all parts with com-pressed air, then reassemble using ATF as a lubricant.

Valve

AssemblyNOTE: Coat all parts with ATF before assembly.

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

ROLLER

SPRING

VALVE BODY

VALVE

CAP

ROLLER

VALVE BODY

VALVE

CAP

SPRING

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

SPRING SEAT

SPRING

VALVE BODY

Install the valve, spring and cap in the valve body. Pushthe cap, then install the valve cap stopper.

STOPPER SEAT

VALVE/SPRING

CAP

Valve Caps

Description

Caps with one projected tip and one flat end areinstalled with the flat end toward the inside of thevalve body.Caps with a projected tip on each end are installedwith the smaller tip toward the inside of the valvebody. The small tip is a spring guide.

TOWARD OUTSIDE OF VALVE BODY

TOWARD INSIDE OF VALVE BODY

Caps with one projected tip and a hollow end areinstalled with the tip toward the inside of the valvebody. The tip is a spring guide.



Caps with hollow ends are installed with the hollowend away from the inside of the valve body.Caps with notched ends are installed with the notchtoward the inside of the valve body.Caps with flat ends and a hole through the center areinstalled with the smaller hole toward the inside ofthe valve body.



Servo Body

Disassembly/lnspection/Reassembly

NOTE:Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.Replace the servo body as an assembly if any parts are worn or damaged.Replace the O-rings and filters.Install the filters in the direction shown.Coat all parts with ATF during assembly.

SNAP RING

O-RINGSReplace.

4TH ACCUMULATOR COVER

4TH ACCUMULATOR PISTON

SERVO DETENT BASE

SERVO BODYInspect for wear, scratchesand scoring.

FILTERSReplace.Install in this direction.

SERVO VALVE/SHIFTFORK SHAFT

SERVO VALVE COVER

SPRING GUIDE

SNAP RING

SPRING SPECIFICATIONS

O-RINGReplace.

3RD ACCUMULATOR PISTON

O-RINGReplace.

3RD ACCUMULATOR COVERO-RINGSReplace.SNAP RING

Unit: mm (in)

O-RINGReplace.

SPRING GUIDE

O-RINGReplace.

Main Valve Body


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 on page 14-136.Coat all parts with ATF during assembly.

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

CHECK BALLS, 11 1-2 SHIFT VALVE

ROLLER

MAIN ORIFICECONTROL VALVE

MANUAL VALVE

VALVE CAP

2-3 SHIFT VALVE

VALVE SLEEVE3-4 ORIFICECONTROL VALVE

VALVE SLEEVE2-3 ORIFICECONTROL VALVE

3-4 SHIFT VALVE

4TH KICK-DOWNVALVE

MAIN VALVE BODYInspect for wear, scratchesand scoring.

4TH EXHAUSTVALVE

SERVO CONTROLVALVE

ROLLER

SPRING SEAT

CHECK BALLS, 11NOTE: Check balls are marked with asterisk (*)only in this figure.

SPRING SPECIFICATIONSUnit: mm (in)

ATF Pump Body


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 on page 14-136.Coat all parts with ATF during assembly.Install the filters in the direction shown.

VALVE SLEEVE

LOCK-UP CONTROL VALVE

LOCK-UP TIMING VALVE

SPRING SEAT

VALVE CAP

ROLLER

RELIEF VALVE

MODULATOR VALVE ATF PUMP BODYInspect for wear, scratchesand scoring.

TORQUE CONVERTER CHECK VALVE


FILTERReplace.

FILTERReplace.

ATF Pump

Inspection

1. Install the ATF pump gears and ATF pump drivengear shaft in the ATF pump body.

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

ATF PUMP DRIVEGEAR

ATF PUMP DRIVEN GEARGrooved and chamfered sidefacing up.

ATF PUMP BODY ATF PUMP DRIVENGEAR SHAFT

2.

3.

Measure the side clearance of the ATF pump driveand driven gears.

ATF Pump Gears Side (Radial) Clearance:Standard (New):ATF Pump Drive Gear0.210 - 0.265 mm (0.0083 - 0.0104 in)ATF Pump Driven Gear0.070 - 0.125 mm (0.0028 - 0.0049 in)

ATF PUMPDRIVE GEARInspect teeth forwear and damage.

ATF PUMPDRIVEN GEARInspect teeth forwear and damage.

Remove the ATF pump driven gear shaft. Measurethe thrust clearance of the ATF pump driven gear-to-valve body, with a straight edge and a feelergauge.

ATF Pump Drive/Driven Gear Thrust (Axial) Clearance:Standard (New): 0.03 - 0.05 mm (0.001 - 0.002 in)Service Limit: 0.07 mm (0.003 in)

STRAIGHT EDGE

FEELERGAUGE

Regulator Valve Body


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 on page 14-136.

1. Hold the regulator spring cap in place while removing the stopper bolt. Once the stopper bolt is removed, release thespring cap slowly.

CAUTION: The regulator spring cap can pop out when the stopper bolt is removed.

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, then press the spring cap into the valvebody, and tighten the stopper bolt.

VALVE SLEEVE

COOLER RELIEF VALVE

STOPPER BOLT6 x 1.0 mm12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

REGULATOR VALVE BODYInspect for wear, scratchesand scoring.

REGULATOR SPRING SEAT

REGULATOR SPRING CAP

SPRING SPECIFICATIONS

5 x 0.8 mm8 N-m (0.8 kgf-m,6 Ibf-ft)

VALVE COVERNOTE: Install the burr sideof the valve cover facingthe regulator valve body.

REGULATOR VALVE

Unit: mm (in)

VALVE CAP

ROLLER

LOCK-UP SHIFTVALVE

1st Accumulator/1 st-hold Accumulator


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.Replace the O-rings and sealing washer.

SNAP RING

1ST-HOLD ACCUMULATORCOVER

1ST-HOLD ACCUMULATORSPRING A

1ST-HOLD ACCUMULATORSPRING B

1ST-HOLD ACCUMULATORPISTON

O-RINGReplace.

REAR COVER

SNAP RING

O-RINGReplace.

1ST ACCUMULATOR COVER

1ST ACCUMULATOR SPRING A

1ST ACCUMULATOR SPRING B

O-RINGReplace.

1ST ACCUMULATOR PISTON

O-RINGReplace.

SEALING BOLT10 x 1.25 mm20 N-m (2.0 kgf-m, 14 Ibf-ft)

SEALING WASHERReplace.


2nd Accumulator Body/Throttle Valve Body

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 during assembly.Replace the O-rings and filter.Install the filter in the direction shown.

2ND ACCUMULATORBODY

DOWEL PINS

THROTTLE VALVE BODYSEPARATOR PLATE


O-RINGSReplace.

LINEAR SOLENOID

THROTTLE VALVEBODY

THROTTLE ADJUSTING BOLTNOTE: Do not adjust or remove;this is adjusted at the factory.

2ND ACCUMULATOR PISTON



FILTERReplace.

Throttle Valve Body/Linear Solenoid

Test

1. Connect the linear solenoid harness to the linearsolenoid terminals.

2. Connect the No. 2 (RED: +) terminal of the linearsolenoid connector to the positive battery terminaland the No. 1 (WHT: -) terminal to the negative bat-tery terminal. Check that the throttle valve moves.

3. Repeat the above steps 1 and 2.

NOTE: You can see the movement of the throttlevalve through the fluid passage in the mountingsurface of the throttle valve body.

LINEAR SOLENOID

Replacement

LINEARSOLENOIDCONNECTOR

THROTTLEVALVEBODY Throttle valve moves

in this directionwhile connectingthe battery.

WIRE SIDE OFFEMALE TERMINALS

NOTE: Do not adjustor remove; this isadjusted at the factory.

4.

5.

6.

If the throttle valve binds, or moves sluggishly, orthe linear solenoid does not operate, replace thethrottle valve body/linear solenoid as an assembly.

If the linear solenoid does not operate, disconnectthe linear solenoid harness from the linear solenoidassembly. Connect the battery directly to the linearsolenoid.

If the linear solenoid operates after connecting thebattery, and the throttle valve movement is OK,replace the linear solenoid harness.

NOTE: Throttle valve body/linear solenoid must bereplaced as an assembly.

1. Check the throttle valve body passages for dust ordirt, and replace as an assembly, if necessary.

2. Clean the mounting surface and fluid passages ofthe throttle valve body.

3. Assemble the throttle valve body/linear solenoid tothe 2nd accumulator body.

FLANGE NUTS5 x 0.8 mm6 N-m(0.6 kgf-m, 4 Ibf-ft)


THROTTLE VALVE BODY/LINEAR SOLENOID ASSEMBLY

Mainshaft


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 damage to the O-rings.Locknut has left-hand threads.

SNAP RING

MAINSHAFTCheck splines for excessivewear and damage.Check bearing surface forscoring, scratches and excessivewear.

SEALING RING, 35 mm

SEALING RING, 29 mm

NEEDLE BEARING

SET RING

THRUST WASHERTHRUST NEEDLEBEARING

4TH/REVERSE GEAR

NEEDLE BEARINGS

4TH GEAR COLLAR

THRUST NEEDLEBEARING

THRUST WASHER

4TH/2ND CLUTCHASSEMBLY

O-RINGSReplace.

2ND GEAR THRUST WASHER,37.5 x 56 mmSelective part

THRUST NEEDLE BEARING

2ND GEAR

NEEDLE BEARINGS


LOCKNUT (Flange nut)24 x 1.25 mmReplace.Left-hand threads137 N-m (14.0 kgf-m, 101 Ibf-ft)

CONICAL SPRINGWASHERReplace.1ST CLUTCHASSEMBLY

O-RINGSReplace.

THRUST WASHER


NEEDLE BEARING

1ST GEAR

THRUST WASHER

1ST GEAR COLLAR

TRANSMISSION HOUSINGBEARING

Inspection

Clearance Measurements

NOTE: Lubricate all parts with ATF during assembly.

1. Remove the mainshaft bearing from the transmis-sion housing (see page 14-172).

2. Assemble the parts below on the mainshaft.

NOTE: Do not install the O-rings during inspection.

LOCKNUTLeft-hand threads

- CONICAL SPRING WASHER

1ST CLUTCH ASSEMBLYTHRUST WASHER1ST GEAR COLLARTRANSMISSION HOUSINGBEARINGSNAP RINGTHRUST WASHER4TH GEAR COLLAR

THRUST WASHER

4TH/2ND CLUTCH ASSEMBLY2ND GEAR THRUST WASHERSelective partTHRUST NEEDLE BEARING2ND GEAR

NEEDLE BEARINGS


MAINSHAFT

3. Torque the mainshaft locknut to 29 N-m (3.0 kgf-m,22 Ibf-ft).

NOTE: Mainshaft locknut has left-hand threads.

LOCKNUT29 N-m(3.0 kgf-m, 22 Ibf-ft)

4. Move the 4th/2nd clutch assembly to check the axialclearances.

5. Attach the dial indicator to the mainshaft 2nd gearas shown.

DIAL INDICATOR

4TH/2ND CLUTCH

MAINSHAFT 2ND GEAR 1ST CLUTCH

Mainshaft

Inspection (cont'd)

6. Measure the 2nd gear axial clearance while pushingthe 4th/2nd clutch toward the 1st clutch.

STANDARD: 0.07 - 0.15 mm (0.003 - 0.006 in)

NOTE: Take measurements in at least three places,and use the average as the actual clearance.

7. If the clearance is out of tolerance, remove the 2ndgear thrust washer and measure its thickness.

8. Select and install a new 2nd gear thrust washer,then recheck.

2ND GEAR THRUST WASHER, 37.5 x 56 mm

9. After replacing the 2nd gear thrust washer, makesure that the clearance is within tolerance.

Sub-assembly

NOTE: Lubricate all parts with ATF during assembly. Before installing the O-rings, wrap the shaft splines

with tape to prevent damage to the O-rings. Assemble the mainshaft sub-assembly when assem-

bling the transmission.

1. Assemble the parts below on the mainshaft.

Mainshaft

Countershaft


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 damage to the O-rings.

COUNTERSHAFTCheck splines for excessive wear and damage.Check bearing surface for scoring, scratchesand excessive wear.

REVERSE GEAR COLLAR

NEEDLE BEARING

REVERSE GEARREVERSE SELECTORREVERSE SELECTORHUB4TH GEAR

NEEDLE BEARING

DISTANCE COLLAR, 35 mmSelective part

2ND GEAR


3RD GEAR

NEEDLE BEARING


3RD GEAR COLLAR

3RD CLUTCH ASSEMBLY

O-RINGSReplace.

LOCKNUT (Flange nut)24 x 1.25 mmReplace.137 N-m (14.0 kgf-m, 101 Ibf-ft)


1ST-HOLD CLUTCHASSEMBLYO-RINGSReplace.THRUST WASHER


1ST-HOLD CLUTCH HUB

1ST GEAR

ONE-WAY CLUTCH

NEEDLE BEARINGS

1ST GEAR COLLAR

PARKING GEAR


Countershaft

Inspection

Clearance Measurement

NOTE: Lubricate all parts with ATF during assembly.

1. Remove the countershaft bearing from the trans-mission housing (see page 14-172).

2. Assemble the parts below on the countershaft.

NOTE: Do not install the O-rings during inspection.

LOCKNUTCONICAL SPRINGWASHER1ST-HOLD CLUTCHASSEMBLYTHRUST WASHER1ST GEAR COLLAR

PARKING GEAR


REVERSE GEAR COLLAR

REVERSE SELECTOR HUB

4TH GEAR

3. Torque the countershaft locknut to 29 N-m (3.0 kgf-m,22 Ibf-ft).

LOCKNUT29 N-m(3.0 kgf-m, 22 Ibf-ft)

4. Hold the 4th gear against the distance collar. Measurethe clearance between the 4th gear and the reverseselector hub with a feeler gauge.

NOTE: Take measurements in at least three places,and use the average as the actual clearance.

STANDARD: 0.07 - 0.15 mm (0.003 - 0.006 in)

DISTANCE COLLAR 4TH GEAR

4TH GEAR

FEELER GAUGE

REVERSE SELECTORHUB

REVERSE SELECTORHUB

DISTANCE COLLAR

DISTANCE COLLARSelective part

2ND GEAR

3RD GEAR COLLAR

3RD CLUTCH ASSEMBLY

COUNTERSHAFT

5. If the clearance is out of tolerance, remove the dis-tance collar and measure its length.

Length

6. Select and install a new distance collar, then recheck.

DISTANCE COLLAR, 35mm

No.

1

2

3

4

5

6

7

8

9

10

Part Number

90501 - PW7 - 000

90502 - PW7 - 000

90503 - PW7 - 000

90504 - PW7 - 000

90505 - PW7 - 000

90506 - PW7 - 000

90507 - PW7 - 000

90508 - PW7 - 000

90509 - PW7 - 000

90510-PW7- 000

Thickness

65.65 mm (2.585 in)

65.70 mm (2.587 in)

65.75 mm (2.589 in)

65.80 mm (2.591 in)

65.85 mm (2.593 in)

65.90 mm (2.594 in)

65.95 mm (2.596 in)

66.00 mm (2.598 in)

66.05 mm (2.600 in)

66.10 mm (2.602 in)

7. After replacing the distance collar, make sure thatthe clearance is within tolerance.

Sub-assembly

NOTE:Lubricate all parts with ATF during assembly.Before installing the O-rings, wrap the shaft splineswith tape to prevent damage to the O-rings.Assemble the countershaft sub-assembly when assem-bling the transmission.

1. Assemble the parts below on the countershaft.

REVERSEGEAR COLLAR

REVERSE SELECTORHUB

DISTANCE COLLAR, 35 mmSelective part

COUNTERSHAFT

3RD CLUTCHASSEMBLY

NEEDLE BEARING

REVERSE GEAR

REVERSE SELECTOR

4TH GEAR

NEEDLE BEARING

2ND GEAR


3RD GEAR

NEEDLE BEARING


3RD GEAR COLLAR

O-RINGSReplace.

One-way Clutch


1. Separate countershaft 1st gear from the parking gearby turning the parking gear in the direction shown.

PARKING GEAR

COUNTERSHAFT1ST GEAR

2. Remove the one-way clutch by prying it up with theend of a screwdriver.

ONE-WAY CLUTCHCOUNTERSHAFT1ST GEAR

SCREWDRIVER

3. Inspect the parts as follows:

Inspect 1st gearfor wear and scoring.

Inspect the one-wayclutch for damage andfaulty movement.

Inspect the needlebearing for damage andfaulty movement.

4.

Inspect the parking gearfor wear and scoring.

After the parts are assembled, hold countershaft 1stgear and turn the parking gear in the direction shownto be sure it turns freely. Also make sure the parkinggear does not turn in the opposite direction.

PARKING GEAR

COUNTERSHAFT1ST GEAR

Clutch

Illustrated Index1ST-HOLD CLUTCH 3RD CLUTCH

CLUTCH DRUM

O-RINGSReplace.

CLUTCH PISTON

CHECK VALVE

RETURN SPRING

SPRING RETAINERSNAP RING

CLUTCH PLATESStandard thickness:2.00 mm (0.079 in)

CLUTCH END PLATE

CLUTCH DISCSStandard thickness:1.94 mm (0.076 in)


CLUTCH PISTON

SNAP RING

CLUTCH END PLATE


SNAP RING

SPRING RETAINER

RETURN SPRING

DISC SPRINGInstall in this direction.

CLUTCH DRUM

O-RINGSReplace.

SNAP RING

Clutch

Illustrated Index (cont'd)4TH/2ND CLUTCH

O-RINGSReplace.

CLUTCH PISTON

CHECK VALVE

RETURN SPRING

SPRING RETAINER

SNAP RING


CLUTCH END PLATE

SNAP RING

CLUTCH DISCSStandard thickness1.94 mm (0.076 in)



CLUTCH PISTON

SNAP RING

CLUTCH END PLATE


SPRING RETAINER

RETURN SPRING


4TH CLUTCH DRUM

2ND CLUTCH DRUM

O-RINGSReplace.

SNAP RING

1ST CLUTCH

CHECK VALVE

SPRING RETAINER

RETURN SPRING

SNAP RING


CLUTCH DRUM

O-RINGSReplace.

CLUTCH PISTON



CLUTCH END PLATE

SNAP RING

Clutch

Disassembly1. Remove the snap ring, then remove the clutch end

plate, clutch discs, and plates.

SCREWDRIVER

SNAP RING

2. Remove the disc springs.

NOTE: The 1st-hold clutch does not have a discspring.

DISC SPRING

1ST and 4TH CLUTCH

3. Install the special tools as shown.

NOTE: For 1st, 3rd, and 1st-hold clutches.

CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE - PX40100


or07HAE - PL50100

CLUTCH SPRINGCOMPRESSORBOLT ASSEMBLY07GAE - PG40200 or07GAE - PG4020A

NOTE: For 2nd and 4th clutches.




or07HAE - PL50100

2ND and 3RD CLUTCH

DISC SPRING

CAUTION: If either end of the special tool is set over anarea of the spring retainer which is unsupported by thereturn spring, the retainer may be damaged. Be sure thespecial tool is adjusted to have full contact with thespring retainer.

Set here.

SPECIAL TOOL

SPRING RETAINER

4. Compress the return spring.

5. Remove the snap ring. Then remove the special tools,spring retainer and return spring.

SNAP RING RETURN SPRING

6.

SPRING RETAINER

Wrap a shop rag around the clutch drum, and applyair pressure to the oil passage to remove the piston.Place a finger tip on the other end while applyingair pressure.

OSHA-APPROVED30 psi NOZZLE

CLUTCHDRUM

PISTON

Clutch

Reassembly

NOTE:Clean all parts thoroughly in solvent or carburetorcleaner, and dry them with compressed air.Blow out all passages.Lubricate all parts with ATF before assembly.

1. Inspect the check valve; if it's loose, replace the piston.

CHECK VALVE

PISTON

2. Install new O-rings on the piston.

O-RINGS

PISTON

PISTON

O-RINGO-RING

3. Install the piston in the clutch drum. Apply pressureand rotate to ensure proper seating.

NOTE: Lubricate the piston O-ring with ATF beforeinstalling.

CAUTION: Do not pinch the O-ring by installing thepiston with too much force.

PISTON

CLUTCH DRUM

4. Install the return spring and spring retainer, and posi-tion the snap ring on the retainer.

SNAP RING

SPRING RETAINER

RETURN SPRING

CLUTCH DRUM

5. Install the special tools as shown.

NOTE: For 1st, 3rd and 1st-hold clutches


NOTE: For 2nd and 4th clutches



CLUTCH SPRINGCOMPRESSORATTACHMENT07LAE-PX40100

or07HAE-PL50100



or07HAE - PL50100

CAUTION: If either end of the special tool is setover an area of the spring retainer which is unsup-ported by the return spring, the retainer may bedamaged. Be sure the special tool is adjusted tohave full contact with the spring retainer.

Set here.

Do not set here.

SPECIAL TOOL

SPRING RETAINER

6. Compress the return spring.

Clutch

Reassembly (cont'd)

7. Install the snap ring.

SNAP RING

8. Remove the special tools.

9. Install the disc spring.

NOTE:Except 1st-hold clutch: the 1st-hold clutch doesnot have a disc spring.Install the disc spring in the direction shown.

DISC SPRING

Install in this direction.

2ND and 3RDCLUTCH

CLUTCH DRUMPISTON

DISC SPRING

Install in this direction.

1ST and 4TH CLUTCH

10. Soak the clutch discs thoroughly in ATF for a mini-mum of 30 minutes.

11. Starting with a clutch plate, alternately install theclutch plates and discs. Install the clutch end platewith the flat side toward the disc.

NOTE: Before installing the plates and discs, makesure the inside of the clutch drum is free of dirt orother foreign matter.

CLUTCH END PLATE

CLUTCHDISC

12. Install the snap ring.

SCREWDRIVER

SNAP RING

13. Measure the clearance between the clutch end plateand top disc with a dial indicator.Zero the dial indicator with the clutch end plate low-ered, and lift it up to the snap ring. The distance thatthe clutch end plate moves is the clearance betweenthe clutch end plate and top disc.

NOTE: Measure at three locations.

Clutch End Plate-to-Top Disc Clearance:

Clutch

1st2nd3rd4th

1st-hold

Service Limit

0.65 - 0.85 mm (0.026 - 0.033 in)0.55 - 0.75 mm (0.022 - 0.030 in)0.55 - 0.75 mm (0.022 - 0.030 in)0.55 - 0.75 mm (0.022 - 0.030 in)0.80 - 1.00 mm (0.031 - 0.039 in)

DIAL INDICATOR

SNAP RING

CLUTCH ENDPLATE Clearance

TOP DISC

14. If the clearance is not within the service limits, selecta new clutch end plate from the following table.

NOTE: If the thickest clutch end plate is installed,but the clearance is still over the standard, replacethe clutch discs and clutch plates.

NUMBERThickness

CLUTCH END PLATE

2ND and 4TH CLUTCH END PLATE

Plate No.123456789

Part Number22631 - PR9 - 00322632 - PR9 - 00322633 - PR9 - 00322634 - PR9 - 00322635 - PR9 - 00322636 - PR9 - 00322637 - PR9 - 00322638 - PR9 - 00322639 - PR9 - 003

Thickness mm (in)2.1 (0.083)2.2 (0.087)2.3 (0.091)2.4 (0.094)2.5 (0.098)2.6 (0.102)2.7 (0.106)2.8 (0.110)2.9 (0.114)

1ST CLUTCH END PLATE

Plate No.1234567891011121314

Part Number22551 - PF4 - 00022552 - PF4 - 00022553 - PF4 - 00022554 - PF4 - 00022555 - PF4 - 00022556 - PF4 - 00022557 - PF4 - 00022558 - PF4 - 00022559 - PF4 - 00022560 - PF4 - 00022561 - PF4 - 00022562 - PF4 - 00022563 - PF4 - 00022564 - PF4 - 000

Thickness mm (in)2.1 (0.083)2.2 (0.087)2.3 (0.091)2.4 (0.094)2.5 (0.098)2.6 (0.102)2.7 (0.106)2.8 (0.110 )2.9 (0.114 )3.0 (0.118 )3. 1 (0.122)3.2 (0.126)3.3 (0.130)3. 4 (0.134)

3RD CLUTCH END PLATE

Plate No.45678910111213

Part Number22554 - PF4 - 00022555 - PF4 - 00022556 - PF4 - 00022557 - PF4 - 00022558 - PF4 - 00022559 - PF4 - 00022560 - PF4 - 00022561 - PF4 - 00022562 - PF4 - 00022563 - PF4 - 000

Thickness mm (in)2.4 (0.094)2.5 (0.098)2.6 (0.102 )2.7 (0.106)2.8 (0.110 )2.9 (0.114 )3.0 (0.118 )3. 1 (0.122)3. 2 (0.126)3.3 (0.130)

1ST-HOLD CLUTCH END PLATE

Plate No.345678910

Part Number22553 - PF4 - 00022554 - PF4 - 00022555 - PF4 - 00022556 - PF4 - 00022557 - PF4 - 00022558 - PF4 - 00022559 - PF4 - 00022560 - PF4 - 000

Thickness mm (in)2.3 (0.091)2.4 (0.094)2.5 (0.098)2.6 (0.102)2.7 (0.106)2.8 (0.110)2.9 (0.114 )3.0 (0.118 )

1st-hold Clutch Bearing

Replacement

1. Remove the 1st-hold clutch bearing using a bearingpuller.

BEARING SEPARATOR, 0 - 4 1/2 in.(Commercially available)

COLLAR

1ST-HOLD CLUTCH

2. Install a new bearing using the special tool as shown.

NOTE: Drive in the bearing until it fully bottoms.

DRIVER I.D. 40 mm07746-0030100

1ST-HOLD CLUTCHBEARING

1ST-HOLD CLUTCH

Secondary Driven Gear Shaft

Components

SET RINGReplace.

TAPERED ROLLERBEARING

SECONDARY DRIVEN GEARSHAFT


SECONDARY DRIVEN GEARSHAFT OIL SEALReplace.

EXTENSION SHAFT

Disassembly

1. Remove the set ring.

2. Remove the extension shaft from the secondarydriven gear shaft.

SET RINGReplace.

Oil Seal Replacement

1. Remove the oil seal from the secondary driven gearshaft.

OIL SEALReplace.

SCREWDRIVER

2. Install the oil seal into the secondary driven gearshaft using the special tools as shown.

DRIVER07749 - 0010000

ATTACHMENT,42 x 47 mm07746 - 0010300


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 bear-ing preload (page 14-168).

1. Remove the tapered roller bearings from the sec-ondary driven gear shaft using a press.

PRESS

COLLAR

SECONDARYDRIVEN GEARSHAFT

BEARING SEPARATOR, 0 - 4 1/2 in.(Commercially available)

2. Install the bearings using the special tool and a pressas shown.

NOTE: Press the bearings in squarely until they bot-tom.

40 mmUse this side fortransmission housingside bearing.

ATTACHMENT40 x 50 mm07LAD-PW50601

50 mmUse this side fortorque converterhousing side bearing.

PRESS

STEEL PLATE

ATTACHMENT,40 x 50 mm07LAD-PW50601


SECONDARY DRIVEN GEAR

Tapered Roller Bearing Outer Race Replacement

NOTE:Replace the bearing with a new one whenever theouter race is to be replaced.Do not use shim(s) on the torque converter housingside.Adjust preload after replacing the bearing and outerrace.Coat all parts with ATF during installation.

1. Remove the bearing outer race from the transmissionhousing and torque converter housing by heating thehousing to about 212F (100C).

CAUTION: Do not heat the housing in excess of212F (100C).

HEAT GUN

THRUST SHIMSelective partTransmission housingonly.

HOUSING OUTER RACE

2. Install the outer race in the torque converter hous-ing, using the special tools as shown.

DRIVER07749-0010000

BEARING DRIVERATTACHMENT07GAD-SD40101

3. Install the thrust shim and outer race in the trans-mission housing, using the special tools as shown.

BEARING OUTERRACE

THRUST SHIM.68 mmSelective part


DRIVER07749-0010000

ATTACHMENT,72 x 75 mm07746-0010600


Tapered Roller Bearing Preload Adjustment

NOTE: If the transmission housing, torque converterhousing, secondary driven gear shaft, tapered rollerbearing, outer race or thrust shim were replaced, thebearing preload must be adjusted.

1. Remove the oil seals from both housing.

2. Remove the bearing outer race and thrust shim fromthe transmission housing by heating the housing toabout 212F (100C) with a heat gun.

CAUTION:Do not heat the housing in excess of 212F(100C).Replace the tapered roller bearing when theouter race is to be removed.Do not use a shim on the torque converter hous-ing side.

NOTE: Let the transmission housing cool to the roomtemperature before adjusting the bearing preload.

HEAT GUN

THRUST SHIMSelective partTransmission housingonly.

HOUSINGOUTER RACE

3. Select the 1.98 mm (0.078 in) thrust shim from themiddle of the table below.

THRUST SHIM 68 mm

No.ABCDEFGHIJKLMNOPQRSTUVWXYz

AAABACAD

Part Number

2394 1-PW5- 00023942 - PW5 - 00023943 - PW5 - 00023944 - PW5 - 00023945 - PW5 - 00023946 - PW5 - 00023947 - PW5 - 00023948 - PW5 - 00023949 - PW5 - 00023950 - PW5 - 00023951 - PW5 - 00023952 - PW5 - 00023953 - PW5 - 00023954 - PW5 - 00023955 - PW5 - 00023956 - PW5 - 00023957 - PW5 - 00023958 - PW5 - 00023959 - PW5 - 00023960 - PW5 - 0002396 1-PW5- 00023962 - PW5 - 00023963 - PW5 - 00023964 - PW5 - 00023965 - PW5 - 00023966 - PW5 - 00023967 - PW5 - 00023968 - PW5 - 00023969 - PW5 - 00023970 - PW5 - 000

Thickness mm (in)

1.56 (0.061)1.59 (0.063)1.62 (0.064)1.65 (0.065)1.68 (0.066)1.71 (0.067)1.74 (0.069)1.77 (0.070)1.8 0 (0.071)1.83 (0.072)1.86 (0.073)1.89 (0.074)1.92 (0.076)1.95 (0.077)1.98 (0.078)2.01 (0.079)2.04 (0.080)2.07 (0.081)2.10 (0.083)2.13 (0.084)2.16 (0.085)2.19 (0.086)2.22 (0.087)2.25 (0.089)2.28 (0.090)2.31 (0.091)2.34 (0.092)2.37 (0.093)2.40 (0.094)2.43 (0.096)

4. After installing the thrust shim, install the outer racein the transmission housing using the special tools(see page 14-167).

NOTE:Install the outer race squarely in the transmissionhousing.Check that there is no clearance between theouter race, shim and transmission housing.

5. Install the sealing bolt to the secondary driven gearshaft and torque it to 20 N-m (2.0 kgf-m, 14 Ibf-ft).

6. With the mainshaft and countershaft removed, installthe secondary driven gear shaft, and torque the trans-mission housing.

NOTE: Install the gasket when checking startingtorque.

10 x 1.25 mm44 N-m (4.5 kgf-m,33 Ibf-ft)10 Bolts

TRANSMISSIONHOUSING

DOWEL PIN

GASKET

DOWEL PIN

SEALING BOLT20 N-m (2.0 kgf-m,14 Ibf-ft)

DOWEL PINSECONDARYDRIVEN GEAR

TORQUECONVERTERHOUSING

10 x 1.25 mm44 N-m (4.5 kgf-m,33 Ibf-ft)

8 x 1.25 mm33 N-m (3.4 kgf-m,25 Ibf-ft)

7. Rotate the secondary driven gear shaft in both direc-tions to seat the bearing.

8. Measure the starting torque of the secondary drivengear shaft with a torque wrench.

STANDARD: 2.3 - 3.2 N-m(23 - 33 kgf-cm, 20 - 29 Ibf-in)

TORQUE WRENCH

NOTE:Measure the starting torque at normal room tem-perature in both directions.Changing the shim to the next size will increase ordecrease starting torque about 0.3 - 0.4 N-m (3 -4 kgf-cm, 3-3 Ibf-in).To increase the starting torque, increase thethickness of the shim. To decrease the startingtorque, decrease the thickness of the shim.

Oil Seals

Removal Installation

1. Remove the oil seal from the transmission housing.

TRANSMISSIONHOUSING

OIL SEALReplace.

2. Remove the oil seal from the torque converter hous-ing.


OIL SEALReplace.

1. Install the oil seal in the transmission housing usingthe special tool as shown.

STEEL PLATE

ATTACHMENT,40 x 50 mm, I.D.07LAD - PW50601

Use this side.

OIL SEAL10.5-11.5 mm(0.41-0.45 in)

2. Drive the oil seal into the torque converter housingusing the special tools as shown.

3. Install the snap ring in the torque converter housing.

DRIVER07749-0010000

OIL SEAL

PINION COVER DRIVER ATTACHMENT07LAD-PW50500

SNAP RING

6.5 mm(0.26 in)

Torque Converter Housing Bearings

Mainshaft Bearing/Oil Seal Replacement

1. Drive out or pull up the mainshaft bearing and oil sealusing the special tools as shown.

DRIVER07749-0010000

ATTACHMENT,07947-6340500

TORQUE CONVERTER HOUSING

3/8" - 16 SLIDE HAMMER(Commercially available)

ADJUSTABLEBEARING PULLER,25 - 40 mm07736-A01000A

2. Drive in the new mainshaft bearing until it bottomsin the housing using the special tools as shown.

DRIVER07749-0010000

ATTACHMENT, 62 x 68 mm07746-0010500

3. Install the new oil seal flush with the housing usingthe special tools as shown.

DRIVER07749-0010000

ATTACHMENT, 72 x 75 mm07746-0010600

Torque Converter HousingBearing

Transmission HousingBearing

Countershaft Bearing Replacement

1. Remove the countershaft roller bearing using thespecial tool as shown.

3/8" - 16 SLIDE HAMMER(Commercially available)

ADJUSTABLEBEARINGPULLER.2540 mm07736-A01000A

2. Install the ATF guide plate.

3. Drive the new bearing into the housing using thespecial tools as shown.

DRIVER07749-0010000

ATTACHMENT,62 x 68 mm07746-0010500

Replacement

ATF GUIDE PLATE

1. To remove the mainshaft and countershaft bearingsfrom the transmission housing, expand each snapring with the snap ring pliers, then push the bearingout.

NOTE: Do not remove the snap rings unless it'snecessary to clean the grooves in the housing.

Remove

LUBRICATION PIPE

TRANSMISSIONHOUSING

MAINSHAFTBEARING

COUNTERSHAFTBEARING

2. Expand each snap ring with the snap ring pliers,insert the new bearing part-way into it, then releasethe pliers. Push the bearing down into the transmis-sion until the ring snaps in place around it.

NOTE: Install with groove side of the bearing facinginside the transmission housing.

Install

GROOVE

Reverse Idler Gear Parking Brake Pawl

Installation

1. Coat the reverse idler gear shaft, needle bearingand new O-rings with lithium grease lightly.

2. Assemble new O-rings and needle bearing on thereverse idler gear shaft.

3. Install the reverse idler gear shaft in the reverseidler gear shaft holder, aligning the D-shaped cutoutof the shaft with the D-shaped area of the holder.

REVERSE IDLERGEAR SHAFT HOLDER

REVERSE IDLERGEAR SHAFT

O-RINGSReplace. NEEDLE BEARING

4. Install the reverse idler gear into the transmissionhousing.

5. Install the reverse idler gear shaft holder assemblyin the transmission housing, then tighten the bolts.

TRANSMISSIONHOUSING

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

REVERSE IDLERGEAR SHAFT/HOLDERASSEMBLY

REVERSE IDLER GEAR

Installation

1. Install the hooked end of the parking brake pawlspring in the hole of the parking brake pawl.

2. Place them on the transmission housing aligningwith shaft holes of the parking brake pawl and trans-mission housing.

3. Install the parking brake pawl shaft on the transmis-sion housing.

4. Install the parking brake pawl stopper on the trans-mission housing.

PARKING BRAKEPAWL

PARKING BRAKESTOPPER SHAFT PARKING BRAKEPAWL SPRING

PARKING BRAKEPAWL SHAFT


Parking Brake Roller Rod

Adjustment

1. Move the detent lever to the position.

2. Measure the clearance between the parking brakeroller rod and the transmission housing as shown.

STANDARD: 3.8 - 4.3 mm (0.15 - 0.17 in)

Measuring Clearance

ROLLER

TRANSMISSIONHOUSING

DETENT LEVER

ROLLER ROD

3. If the clearance is out of tolerance, select and installa new parking brake roller rod.

PARKING BRAKE ROLLER ROD

Mark

L Length


Mark

1 or None

2

0

3

Part Number

24550 -PW4- 010

24560 -PW4- 010

24580 -PW4- 010

24590 - PW4 - 000

Length "L"

36.0 mm (1.417 in)

35.6 mm (1.402 in)

36.4 mm (1.433 in)

36.2 mm (1.425 in)

4. After replacing the parking brake roller rod, makesure that the clearance is within tolerance.

Control Shaft/Detent Spring

Disassembly

NOTE: It is necessary to disassemble the control shaft and/or detent spring when maintenance is required.

1. Remove the two special bolts, lock washer, detent spring plate and detent spring.

2. Remove the special bolt securing the parking brake roller guide, then remove the parking brake roller guide with twodowel pins from the transmission housing.

3. Remove the three lock bolts with lock washers from the control shaft.

4. Pull the control shaft out and remove the detent lever, shift arm roller, parking brake stopper, parking brake shift arm,parking brake roller rod, parking brake shift arm spring and control shaft collar.

CONTROL SHAFT

PARKING BRAKE SHIFT ARM

PARKING BRAKESTOPPER

DOWEL PINS PARKING BRAKEROLLER GUIDE

A/T GEARPOSITIONSWITCH

TRANSMISSIONHOUSING

DETENT LEVERLOCK WASHERReplace.

SHIFT ARM ROLLER

SPECIAL BOLTDETENT SPRING

DETENT SPRINGPLATE

LOCK WASHERReplace.

SPECIAL BOLTS

LOCK BOLT

PARKING BRAKEROLLER ROD

LOCK BOLT

LOCK WASHERReplace.

CONTROL SHAFTCOLLAR

PARKING BRAKE SHIFTARM SPRING

Control Shaft/Detent Spring

Reassembly

NOTE:Coat all parts with ATF.Replace the lock washers.

1. Insert the control shaft into the torque converterhousing, then install the control shaft collar andparking brake shift arm spring on the control shaft.

2. Set the parking brake shift arm with the parkingbrake stopper, then insert the control shaft into thehole of the parking brake shift arm/parking brakestopper assembly.

3. Install the parking brake roller rod with the shift armroller on the parking brake shift arm, then install thedetent lever on the control shaft.

CAUTION:Install the parking brake roller rod with the rivetfacing the detent lever.Install the shift arm roller with its flange sidefacing the detent lever.

Rivet side


LOCK WASHERReplace.

LOCK BOLT6 x 1.0 mm14 N-m (1.4 kgf-m, 10 Ibf ft)

4. Align the cutout of the control shaft with the A/T gearposition switch, then insert the control shaft in theA/T gear position switch.

5. Install the lock bolts with new lock washers on thecontrol shaft, and tighten the bolts. Then bend thelock washers against the bolt head.

6. Move the detent lever to any gear other than theposition.

CAUTION: If the detent lever is in the positionwhen installing the detent spring; you may damagethe parking brake roller guide.

7. Install the parking brake roller guide on the trans-mission housing with the two dowel pins and thespecial bolt.

8. Install the detent spring, detent spring plate, lockwasher and the two special bolts.

9. Tighten the bolts then bend the lock washer.

LOCK WASHERReplace.

LOCK BOLT6 x 1.0 mm14 N-m (1.4 kgf-m, 10 Ibf-ft)

LOCK WASHERReplace. LOCK BOLT

6 x 1.0 mm14 N-m(1.4 kgf-m, 10 Ibf-ft)

SPECIAL BOLT8 x 1.25 mm29 N-m (3.0 kgf-m, 22 Ibf-ft)

LOCK WASHERReplace.

PARKING BRAKEROLLER RODInstall in this direction

SHIFT ARM ROLLERInstall in this direction.

SPECIAL BOLTS8 x 1.25 mm29 N-m (3.0 kgf-m, 22 Ibf-ft)

Transmission

Reassembly

NOTE:Coat all parts with ATF.Replace the following parts:

O-ringsLock washersGasketsMainshaft and countershaft locknuts and conical disc springsSealing washers

TORQUE:6 x 1.0 mm Bolts: 12 N-m (1.2 kgf-m, 8.7 Ibf-ft)8 x 1.25 mm Bolts: 18 N-m (1.8 kgf-m, 13 Ibf-ft)5 x 0.8 mm Flange nuts: 6 N-m (0.6 kgf-m, 4 Ibf-ft)



2ND ACCUMULATORBODY

ATF FEED PIPES, 2.

THROTTLEVALVE BODYSEPARATORPLATE


2ND ACCUMULATORPISTON

THROTTLE VALVE BODY/LINER SOLENOIDASSEMBLY

ATF FEED PIPES, 2

REGULATOR VALVE BODY

STATOR SHAFT

STOPPER SHAFT

REGULATOR SEPARATORPLATE

ATF PUMP BODY

ATF FEED PIPE



ATF PUMP DRIVE GEAR

ATF PUMP DRIVEN GEAR

TORQUE CONVERTERCHECK VALVE

TORQUE CONVERTERCHECK VALVE SPRING

ATF PUMP BODY SEPARATORPLATE

ATF PUMP DRIVEN GEAR SHAFT


TORQUE CONVERTERHOUSING LINEAR SOLENOID

HARNESS CONNECTOR

6 x 1.0 mm BOLT8 N-m (0.8 kgf-m,6 Ibf-ft)

5 x 0.8 mmFLANGE NUTS2 Nuts

1. Install the linear solenoid harness and linear solenoidharness connector into the torque converter housing.

2. Install the ATF pump body separator plate and threedowel pins on the torque converter housing.

CAUTION: Take care not to pinch the linear solenoidharness.

3. Install the ATF pump drive gear, ATF pump drivengear, ATF pump driven gear shaft, torque convertercheck valve, and spring on the torque converterhousing.

NOTE: Install the ATF pump driven gear with itsgrooved and chamfered side facing down.

ATF PUMPDRIVE GEAR

ATF PUMP DRIVENGEAR SHAFT

ATF PUMPDRIVEN GEAR

Grooved and chamferedside faces separatorplate.

ATF PUMP BODYSEPARATOR PLATE

4. Install the ATF pump body with three 8 mm bolts andtwo 6 mm bolts. Make sure the ATF pump drive gearrotates smoothly in the normal operating direction,and the ATF pump driven gear shaft moves smoothlyin the axial and normal operating directions.

5. If the ATF pump drive gear and ATF pump drivengear shaft do not move freely, loosen the ATF pumpbody bolts, realign the ATF pump driven gear shaft,and then retighten to the specified torque.

CAUTION: Failure to align the ATF pump drivengear shaft correctly will result in a seized ATF pumpdriven gear or ATF pump driven gear shaft.

6.

ATF PUMPDRIVENGEAR

ATF PUMPDRIVE GEAR

ATF PUMP DRIVENGEAR SHAFT

Install the throttle valve body/linear solenoid on the2nd accumulator body with two dowel pins, throttlevalve body separator plate, and harness clamp (fourbolts).

7. Install the 2nd accumulator piston and 2nd accumu-lator spring in the 2nd accumulator body, then installthe 2nd accumulator body on the torque converterhousing (six bolts).

8. Install the regulator separator plate on the ATF pumpbody with two dowel pins.

9. Install the stator shaft with a new O-ring and stoppershaft.

10. Install the regulator valve body (nine bolts).

11. Connect the linear solenoid harness to the linearsolenoid terminal, then tighten the two flange nutsto 6 N-m (0.6 kgf-m, 4 Ibf-ft)

12. Tighten the linear solenoid harness connector boltto 8 N-m (0.8 kgf-m, 6 Ibf-ft)

13. Install the ATF feed pipe in the ATF pump body, thetwo ATF feed pipes in the torque converter housing,and the two ATF feed pipes in the 2nd accumulatorbody.

Transmission

Reassembly (cont'd)

6 x 1.0 mm12 N-m (1.2 kgf-m, 8.7 Ibf-ft) CONNECTOR HOLDER


TRANSMISSION HOUSINGMOUNTING BOLTS10 x 1.25 mm10 Bolts44 N-m (4.5 kgf-m, 33 Ibf-ft)

TRANSMISSIONHOUSING GASKET.Replace.


TRANSMISSION HOUSINGMOUNTING BOLTS8 x 1.25 mm3 Bolts33 N-m (3.4 kgf-m, 25 Ibf-ft)

COUNTERSHAFT SPEEDSENSOR

6 x 1.0 mm12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

MAINSHAFT SPEEDSENSOR


SECONDARY DRIVENGEAR/SHAFT

EXTENSION SHAFT

CONNECTOR BRACKETS


TRANSMISSION HOUSINGMOUNTING BOLT10 x 1.25 mm44 N-m (4.5 kgf-m, 33 Ibf-ft)

DOWEL PINS, 3

WASHER(M1WA-3010520~)

14. Install the reverse idler gear and reverse idler gearshaft assembly in the transmission housing (see page14-173).

15. Assemble the mainshaft sub-assembly (see page14-150).

16. Assemble the countershaft sub-assembly (see page14-153).

17. Install the secondary driven gear shaft in the torqueconverter housing.

18. Install the mainshaft sub-assembly and the counter-shaft sub-assembly together in the torque converterhousing.



19. Install three dowel pins and a new gasket on thetorque converter housing.

20. Place the transmission housing on the torque con-verter housing.

CAUTION: Make sure that the mainshaft and coun-tershaft speed sensors are not installed on thetransmission housing before installing the trans-mission housing on the torque converter housing.

21. Install the transmission housing mounting bolts, andtorque them in two or more steps in the sequenceshown.

22. Install the 10 mm bolt and three 8 mm bolts to thetransmission housing from the torque converter hous-ing side, and torque them.

23. Install the mainshaft and countershaft speed sensorson the transmission housing.

24. Install the connector brackets and connector holderon the transmission housing.

Transmission

Reassembly (cont'd)

LOCKNUTSReplace.Mainshaft locknut has left-hand threads.

CONICAL SPRING WASHERReplace.

1ST-HOLD CLUTCHASSEMBLY

THRUST WASHER


1ST-HOLD CLUTCH HUB

1ST GEAR

ONE-WAY CLUTCH

NEEDLE BEARINGS

1ST GEAR COLLAR

PARKING GEAR

COUNTERSHAFT

MAINSHAFT

CONICAL SPRING WASHERReplace.

1ST CLUTCH ASSEMBLY

THRUST WASHER


NEEDLE BEARING

1ST GEAR

THRUST WASHER

1ST GEAR COLLAR

A/T GEAR POSITIONSWITCH HARNESS

25. Install the parking brake pawl, spring, pawl shaft andstopper shaft on the transmission housing (see page14-173).

26. Shift to any gear other than the position by turn-ing the control shaft or the detent lever.

27. Install the parking gear, countershaft 1st gear collarand needle bearings on the countershaft.

28. Assemble the one-way clutch in the countershaft1st gear, then install them on the countershaft.

29. Install the mainshaft 1st gear collar and the thrustwasher on the mainshaft.

30. Install the O-ring on the mainshaft and countershaft.

NOTE: Before installing the O-rings, wrap the shaftsplines with tape to prevent damage to the O-rings.

31. Install the thrust washer, thrust needle bearing, nee-dle bearing and mainshaft 1st gear in the 1st clutchassembly, then install them on the mainshaft.

32. Install the thrust washer, thrust needle bearing and1st-hold clutch hub in the 1st clutch assembly, theninstall them on the countershaft.

33. Install the special tool onto the mainshaft as shown.

MAINSHAFT HOLDER07GAB - PF50100 or07GAB - PF50101

34. Engage the parking brake pawl with the parking gearby turning the detent lever to the E position.

35. Coat new conical spring washers with ATF, theninstall them and new locknuts on each shaft.

CAUTION: Install the conical spring washers in thedirection shown.

36. Tighten the locknuts to specified torque using atorque wrench.

TORQUE: 137 N-m (14.0 kgf-m, 101 Ibf-ft)

NOTE: The mainshaft locknut has left-hand threads.

MAINSHAFT LOCKNUTLeft-hand threads

COUNTERSHAFTLOCKNUT

Stamp side

CONICAL SPRINGWASHERSInstall in thisdirection.

37. Stake each locknut into its shaft using a 3.5 mm(0.14 in) punch.

3.5 mm (0.14 in)

0.7 1.2 mm(0.03-0.05 in)

Left-hand threadsmark

Transmission

Reassembly (cont'd)

38. Assemble the lower valve body assembly (see page14-110 and 14-111).

39. Install the two dowel pins on the lower valve bodyassembly.

40. Push the shift fork toward the servo valve body.

41. Install the lower valve body assembly putting themanual valve and detent lever together, the reverseselector and the shift fork together, and joining theATF feed pipes with the ATF feed pipe holes of thetransmission housing.

SHIFT FORKDOWEL PIN

Push shift forkin this direction.

2PCONNECTOR

6 x 50 mm

6 x 50 mm 6 x 40 mm

43. Install the main valve body plate (four bolts).

44. Pass the shift control solenoid valve harness throughthe transmission housing, then install the shift con-trol solenoid valve harness connector (one bolt).

45. Install the harness cover (four bolts).

46. Lightly pull the shift control solenoid valve harnessfrom the harness cover, then bring the shift controlsolenoid valve harness back. Make sure that the shiftcontrol solenoid valve harness is not pinched. If theshift control solenoid valve harness is pinched,loosen the four bolts securing the harness cover thenretighten the bolts.


6 x 20 mm

6 x 50 mm

HARNESS COVER

6 x 40 mm

6 x 50 mm

6 x 45 mm

6 x 50 mm 6 x 40 mm

42. Install the six bolts and torque as shown.


6 x 25 mm

SHIFT CONTROL SOLENOID LVE HARNESSSHIFT CONTROL SOLENOID VA

VALVE HARNESS CONNECTOR

O-RINGReplace

6 x 16 mm8 N-m(0.8 kgf-m,6 Ibf-ft)

6 x 40 mm6 x 50 mm MAIN VALVE

BODY PLATESHIFT CONTROL SOLENOIDVALVE HARNESS

47. Install the ATF strainer with a new O-ring (four bolts).


ATF STRAINER

48. Install the ATF pan with two dowel pins and a newgasket (fifteen bolts) as shown. Make sure that theshift control solenoid valve harness is not pinchedby the ATF pan.


6 x 30 mm

6 x 30 mm

ATF PAN

49. Install four ATF feed pipes in the transmission hous-ing.

50. Install the rear cover with two dowel pins and a newgasket (eight bolts).

51. Install the A/T gear position switch harness clamp onthe rear cover.

REAR COVER

ATF FEED PIPES

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

PARKING BRAKEPAWL STOPPERSHAFT

DOWEL PIN

REAR COVERGASKETReplace.

ATF FEED PIPE

52. Install the A/T gear position switch cover. Tightenthe bolt on the ATF pan side loosely so that there isno clearance between the A/T gear position switchcover and the ATF pan. Then tighten the bolt on therear side cover side to the specified torque, andtighten the bolt on the ATF pan side to the specifiedtorque.

6 x 1.0 mm(Rear cover side)12 N-m (1.2 kgf-m,8.7 Ibf-ft)

REAR COVER

ATF PAN

A/T GEAR POSITIONSWITCH COVER

6 x 1.0 mm(ATF pan side)12 N-m (1.2 kgf-m,8.7 Ibf-ft)

53. Install the ATF cooler pipes on the transmission hous-ing, if necessary.

ATF COOLER PIPE(INLET)

JOINT BOLTS28 N-m (2.9 kgf-m,21 Ibf-ft)Use new sealingwashers, wheninstalling jointbolts.

ATF COOLER PIPE(OUTLET)

54. Install the ATF dipstick.

55. Connect the connectors, and install them on theconnector brackets and connector holder.

Torque Converter/Drive Plate/Ring Gear


6 x 1.0 mm12 N-m(1.2 kgf-m, 8.7 Ibf-ft)

12 x 1.0 mm74 N-m (7.5 kgf-m, 54 Ibf-ft)Torque in a crisscross pattern.

O-RINGReplace.

TORQUE CONVERTERASSEMBLY

WASHER

Transmission

Installation

1. Flush the ATF cooler as described on pages 14-193and 14-194.

2. Install the torque converter securely with a new O-ringon the mainshaft, and install two 14 x 20 mm dowelpins in the torque converter housing.

14 x 20 mmDOWEL PINS


TORQUE CONVERTERO-RINGReplace.

EXTENSIONSHAFT

3. Set the extension shaft, apply Super High TempUrea Grease (P/N 08798 - 9002) to the shaft splines.

DIFFERENTIALCARRIER

EXTENSION SHAFT

DRIVE PINION

5. Place the transmission on a jack, and raise to theengine assembly level.

6. Attach the transmission on the engine, then installthe transmission housing mounting bolts.

TRANSMISSIONHOUSING MOUNTINGBOLT12 x 1.25 mm64 N-m (6.5 kgf-m,47 Ibf-ft)


6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft) TRANSMISSION HOUSING

MOUNTING BOLT12 x 1.25 mm64 N-m (6.5 kgf-m, 47 Ibf-ft)

7. Install the torque converter cover mounting bolt onthe torque converter housing side.

SECONDARY DRIVEN GEARSUPER HIGH TEMPUREA GREASE(P/N 08798-9002)3.5-4.5 g (3.7-4.8 cc)

SUPER HIGH TEMPUREA GREASE(P/N 08798-9002)Fill the opening flushwith the shaft surface.

4. Remove the used grease, then fill the opening of thedrive pinion and extension shaft with Super HighTemp Urea Grease (P/N 08798 - 9002), as shown.

Transmission

Installation (cont'd)

8. Install the mid mount spacer and transmission midmounts while raising the transmission with a jack.

TRANSMISSION

MID MOUNTSPACERInstall in thisdirection.

MID MOUNT10 x 1.25 mm38 N-m (3.9 kgf-m,28 Ibf-ft)

9. Tighten the bolts using an offset wrench and a torquewrench as shown.

MID MOUNTS

OFFSET WRENCH(Commercially available) TORQUE WRENCH

NOTE: When tightening the bolts using an offset wrenchand a torque wrench, the tightening torque value differsfrom torque specification according to a torque wrench.Before tightening the bolts, calculate actual torque valueby following formula.

TORQUEWRENCH

OFFSET WRENCH

Example:Torque Specification: 38 N-m (3.9 kgf-m, 28 Ibf-ft)Effective Length of Torque Wrench: 0.345 (m)Effective Length of Offset Wrench: 0.13 (m)

WASHER

MID MOUNT NUTS10 x 1.25 mm43 N-m (4.4 kgf-m, 32 Ibf-ft)

10. Install the mid mount nuts.

11. Install the transmission housing mounting bolts and26 mm shim.

TRANSMISSION HOUSINGMOUNTING BOLTS12 x 1.25 mm64 N-m(6.5 kgf-m, 47 Ibf-ft)

TRANSMISSION HOUSINGMOUNTING BOLTS12 x 1.25 mm64 N-m (6.5 kgf-m, 47 Ibf-ft)

26 mm SHIM

12. Install a new set ring on the extension shaft groove.

EXTENSION SHAFT SET RING

13. Install the extension shaft.

14. Fill the opening of the extension shaft and 33 mmsealing bolt with Super High Temp Urea Grease (P/N08798-9002) as shown.

SECONDARY DRIVEN GEAR

SET RING

33 mm SEALING BOLT

EXTENSIONSHAFT

SUPER HIGH TEMPUREA GREASE(P/N 08798 - 9002)Fill the opening flush with theshaft surface.

SUPER HIGH TEMPUREA GREASE(P/N 08798 - 9002)4 - 5 g (4.3 - 5.4 cc)

15. Apply liquid gasket (P/N 08718-0001) to the 33 mmsealing bolt threads.

16. Shift the transmission into the position by rotatingthe control shaft.

17. Install the 33 mm sealing bolt.

33 mm SEALING BOLTApply liquid gasket.78 N-m(8.0 kgf-m, 58 Ibf-ft)

Transmission


18. Connect the ATF cooler hoses to the joint pipes (seepage 14-195).

AFT COOLERHOSES INSULATORS

12 x 1.25 mm54 N-m (5.5 kgf-m,40 Ibf-ft)


TRANSMISSIONMOUNT

MOUNTSTOPPER

WASHER

12 x 1.25 mm64 N-m (6.5 kgf-m,47 Ibf-ft)Replace.

19. Install the transmission mount bracket and trans-mission mount.

20. Install the A/T gear position switch harness bracket,then connect the A/T gear position switch connector.

HARNESSBRACKET

A/T GEAR POSITIONSWITCH CONNECTOR

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

21. Install the shift cable holder on the transmissionrear cover.

22. Install the control lever with a new lock washer tothe control shaft.CAUTION: Take care not to bend the shift cable.

23. Install the shift cable cover.

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

SHIFT CABLEHOLDER

6 x 1.0 mm12 N-m (1.2 kgf-m, 8.7 Ibf-ft)

SHIFT CABLECOVER BRACKET

SHIFT CABLE COVER

FLOATINGWASHERS

LOCK WASHERReplace.

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

CONTROL SHAFT6 x 1.0 mm14 N-m (1.4 kgf-m/10 Ibf-ft) CONTROL LEVER

24. Install the exhaust manifold brackets.25. Install exhaust pipe A.26. Install the two exhaust pipe A bracket bolts to the

transmission rear cover.

8 x 1.25 mm27 N-m (2.8 kgf-m,20 Ibf-ft)

8 x 1.25 mm22 N-m (2.2 kgf-m,16 Ibf-ft)

GASKETReplace.

EXHAUST MANIFOLDBRACKETS

EXHAUST PIPE A

GASKETReplace.

SELF-LOCKING NUT10 x 1.25 mm33 N-m (3.4 kgf-m,25 Ibf-ft)Replace.

SELF-LOCKING NUT10 x 1.25 mm54 N-m (5.5 kgf-m, 40 Ibf-ft)Replace.

27. Attach the torque converter to the drive plate witheight bolts and torque:Rotate the crankshaft as necessary to tighten thebolts to 1/2 of the specified torque, then to the finaltorque, in a crisscross pattern.After tightening the last bolt, check that the crankshaftrotates freely.


6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)

6 x 1.0 mm12 N-m (1.2 kgf-m,8.7 Ibf-ft)


28. Install the torque converter cover.

29. Install the transmission ground cable.

TRANSMISSION GROUND CABLE

TRANSMISSIONSUB-HARNESSCONNECTOR

30. Connect the transmission sub-harness connector.

31. Install the control box, then connect the connector.

CONTROL BOX

CONNECTOR

32. Install the lower heat shield cover.

33. Install the battery base and the upper heat shield.

6 x 1.0 mm9.8 N-m (1.0 kgf-m,7.2 Ibf-ft)

LOWER HEATSHIELD COVER

6 x 1.0 mm9.8 N-m (1.0 kgf-m,7.2 Ibf-ft)

UPPER HEATSHIELD COVER

8 x 1.25 mm22 N-m (2.2 kgf-m,16 Ibf-ft)BATTERYBASE

Transmission


34. Install the engine ground cable and ignition coil wireon the upper heat shield cover.

33. Connect the ignition coil wire connector.

36. Install the battery and battery hold-down bracket.

IGNITION COILWIRE CONNECTOR

6 x 1.0 mm9.8 N-m (1.0 kgf-m,7.2 Ibf-ft)

ENGINEGROUND CABLE

37. Refill the transmission with ATF (see page 14-105).

38. Connect the battery positive (+) and negative (-)cables to the battery terminals.

39. Set the parking brake. Start the engine, and shift thetransmission through all gears three times.Check the shift lever operation and the A/T gear posi-tion indicator operation.

40. Let the engine reach operating temperature (thecooling fan comes on) with the transmission in the

or position, then turn it off and check ATFlevel.

41. Road test as described on pages 14-102 and 14-103.

42. Enter the anti-theft code for the radio, then enter thecustomer's radio station presets.

Cooler Flushing

To prevent injury to face and eyes, alwayswear safety glasses or a face shield when using thetransmission flusher.

NOTE: This procedure should be performed before rein-stalling the transmission.

1. Check tool and hoses for wear or cracks before using.If wear or cracks are found, replace the hosesbefore using.

2. Using the measuring cup, fill the tank with 21 ounces(approximately 2/3 full) of biodegradable flushingfluid (J35944 - 20). Do not substitute with any otherfluid. Follow the handling procedure on the fluidcontainer.

3. Secure the flusher filler cap, and pressurize the tankwith compressed air to between 550 - 829 kpa (5.6 -8.45 kgf/cm2, 80-120psi).

NOTE: The air line should be equipped with a watertrap to ensure a dry air system.

4. Hang the tool under the vehicle.

5. Attach the tank's discharge hose to the return lineof the transmission cooler using a clamp.

6. Connect the drain hose to the inlet line on the trans-mission cooler using a clamp.

IMPORTANT:Securely clamp the opposite end of the drain hose to abucket or floor drain.

TRANSMISSION

DISCHARGEHOSE

Water

BUCKET TRANSMISSION COOLERFLUSHERCommercially AvailableKent-Moore J38405-Aor equivalent

7. With the water and air valves off, attach the water andair supplies to the flusher. (Hot water if available.)

OFF

VALVE

8. Turn on the flusher water valve so water will flowthrough the cooler for 10 seconds.

NOTE: If water does not flow through the cooler, itis completely plugged, cannot be flushed, and mustbe replaced.

9. Depress the trigger to mix the flushing fluid into thewater flow. Use the wire clip to hold the trigger down.

10. While flushing with the water and flushing fluid for2 minutes, turn the air valve on for 5 seconds every15-20 seconds to create a surging action.AIR PRESSURE: MAX 845 kpa (8.45 kgf/cm2, 120 psi)

11. Turn the water valve off. Release the trigger, thenreverse the hoses to the cooler so you can flush inthe opposite direction. Repeat steps

Documents

Acura 2.5TL 3.2TL 1995 -1998 Service Manual_Part6