End Cover and Idler Gear Removal/Installation

End Cover Removal

Special Tools Required
Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Remove the transmission range switch cover.
2. Remove the bolts securing the harness clamp (one bolt) and transmission range switch (two bolts), then remove the transmission range switch.
3. Remove the bolts securing the end cover (sixteen bolts), then remove the end cover.





4. For '00-02 models: Remove the pitot pipe (A) and the lubrication pitot pipe (B) from the transmission housing (C), then remove the pitot flange (D) from the mainshaft idler gear (E).





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





7. Cut the lock tabs (A) of each shaft locknut (B) using a chisel (C). Then remove the locknuts and conical spring washers from each shaft.

NOTE:
- Countershaft and secondary shaft locknuts have left-hand threads. Clean the old locknuts; they are used to install the press fit idler gears on the mainshaft and secondary shaft, and the park gear and bearing hub on the countershaft.
- Keep all of the chiseled particles out of the transmission.





8. Remove the special tool (mainshaft holder) from the mainshaft.
9. Remove the mainshaft idler gear (A) and the secondary shaft idler gear (B) with a puller (C).
10. Remove the bearing hub (D) with the puller from the countershaft, then remove the countershaft idler gear (E) and bearings.
11. Remove the park gear (F) with the puller.
12. Remove the park pawl, spring, shaft, and shaft stop.
13. Remove the park lever from the control shaft.
14. Remove the line bolts, then remove the ATF cooler lines.

Park Lever Stop Inspection and Adjustment





1. Set the park lever (A) in the P position.
2. Measure the distance (B) between the park pawl shaft (C) and the park lever roller pin (D).
STANDARD: 84.6 - 85.6 mm (3.33 - 3.37 inch)





3. If the measurement is out of tolerance, select and install the appropriate park lever stop (E) from the table.





PARK LEVER STOP

4. After replacing the park lever stop, make sure the distance is within tolerance.

End Cover and Idler Gears Installation

Special Tools Required
Mainshaft holder 07GAB-PF50101 or 07GAB-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 in this step; bend it aver checking park pawl engagement.
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) to engage with 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 nuts.





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 seat the park gear to 226 Nm (23.0 kgf-cm, 166 ft. lbs.), then remove the locknut and conical spring washer.

NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut.





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 seat the bearing hub/bearing assembly to 164 Nm (17.0 kgf-cm, 123 ft. lbs.).

NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut.





7. Set the dial indicator (A) to the countershaft idler gear (B).





8. Measure the countershaft. idler gear axial clearance in at least three places, while moving the countershaft idler gear (A). Use the average as the actual clearance.
STANDARD: 0.015 - 0.045 mm (0.0006 - 0.0018 inch)
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.





BEARING HUB

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, secondary shaft, and new 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 seat the mainshaft idler gear to 226 Nm (23.0 kgf-m, 166 ft. lbs.).

NOTE: Do not use an impact wrench, always use a torque wrench to tighten the locknut.

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: Do not use an impact wrench, always use a torque wrench to tighten the locknut. Secondary shaft locknut has left-hand threads.

17. Remove the old locknuts and old conical spring washer from the mainshaft and the secondary shaft.
18. Lubricate the threads of each shaft and new locknuts, and 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 locknuts to 167 Nm (17.0 kgf-cm, 123 ft. lbs.).

NOTE:
- Do not use an impact wrench, always use a torque wrench to tighten the locknut.
- Countershaft and secondary shaft locknuts have left-hand threads.





21. Stake each locknut into its shaft using a 3.5 mm punch.





22. For '00-02 models: 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 P 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) along with 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 transmission range switch to N position.

NOTE: The transmission range switch clicks in N position.





28. Set the control shaft (A) to the N position by turning it.

NOTE: Be careful not to squeeze the end of the control shaft tips together when turning into position. If the tips are squeezed together it will cause a faulty shift signal or position due to the play between the control shaft and the switch.





29. Install the transmission range switch (A) loosely on the control shaft (B), then secure it with the bolts. Do not move the transmission range switch when tightening the bolts.
30. Install the transmission range switch cover (C), and install the harness clamp (D) on the clamp bracket (E) on the transmission housing, then 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.