Transmission Reassembly

1. Install the main separator plate and three dowel pins on the torque converter housing. Then install the ATF pump gears and ATF pump driven gear shaft.





2. Install the torque converter check valve and spring, then install the main valve body (one 6 mm bolt and three 8 mm bolts). Make sure the ATF pump drive gear rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft moves smoothly in the axial and normal operating direction.
3. If the ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torque, then recheck.

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

4. Install the cooler check valve and spring on the main valve body, then install the two dowel pins and the regulator separator plate.
5. Install the stator shaft and stator shaft stop.
6. Install the regulator valve body (eight bolts).
7. Install the two dowel pins and the servo separator plate on the main valve body.
8. Install the control shaft in the torque converter housing, then align the manual valve lever of the control shaft to the manual valve guide.





9. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm.

10. Install the servo body and valve cap clip cover ('97 model) (nine bolts).
11. Install the accumulator cover (two bolts).
12. Install the ATF strainer (one bolt).
13. Install the servo detent base (two bolts).
14. Install the accumulator body (six bolts).





15. Install the two ATF feed pipes in the servo body, four pipes in the regulator valve body, and one pipe in the main valve body.
16. Install the differential assembly, countershaft subassembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing.
17. Install the countershaft 4th gear and reverse selector hub on the countershaft.





18. Turn the shift fork shaft so the large chamfered hole is facing the fork bolt hole. Then install the shift fork and reverse selector together on the shift fork shaft and countershaft. Secure the shift fork to the shift fork shaft with the lock bolt and a new lock washer, then bend the lock washer against the bolt head.
19. Install the needle bearing, countershaft reverse gear, and countershaft 2nd gear on the countershaft.





20. Install the reverse idler gear in the transmission housing in the direction shown, then move it the direction shown.
21. Align the spring pin of the control shaft with the transmission housing groove by turning the control shaft.
22. Install three dowel pins and a new gasket on the torque converter housing.





23. Place the transmission housing on the torque converter housing.





24. Install the transmission housing mounting bolts along with the transmission hanger/connector bracket, transmission hangers, and transmission ground terminal bracket. Tighten the bolts in two or more steps in the sequence shown.
25. Install the countershaft speed sensor on the transmission housing.
26. Install the A/T clutch pressure control solenoid valve A/B assembly, three ATF feed pipes, new 0rings, and a new gasket on the transmission housing.





27. Coat the reverse idler gear shaft, needle bearing, and new O-rings with lithium grease lightly. Assemble the new O-rings and needle bearing on the reverse idler gear shaft, then install the reverse idler gear shaft in the reverse idler gear shaft holder, aligning the D-shaped cut out of the shaft with the D-shaped area of the holder.





28. Engage the reverse idler gear with the counter shaft reverse gear and mainshaft reverse gear, then install the reverse idler gear shaft/holder assembly on the transmission housing.





29. Install the park lever on the control shaft, then install the lock bolt with a new lock washer.

NOTE: Do not bend the lock tab of the lock washer in this step; bend it after checking the park pawl engagement in step 50.

30. Coat 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.





31. Install the park gear using the old locknut and a collar. Hold the park pawl to engage with the park gear, then tighten the old locknut until the shaft splines come out slightly over the park gear splines.





32. Remove the locknut and the collar, then install only the bearing hub/bearing assembly and old conical spring washer. Tighten the old locknut to seat the park gear to the specified torque, then remove the locknut and conical spring washer.





33. Remove the bearing hub/bearing assembly using a puller as shown.





34. Install the thrust needle bearing, needle bearing, countershaft idler gear, thrust needle bearing, bearing hub/bearing assembly, and the old conical spring washer. Then tighten the old locknut to seat the bearing hub/bearing assembly to the specified torque.





35. Set the dial indicator to the countershaft idler gear as shown.





36. Measure the countershaft idler gear axial clearance while moving the countershaft idler gear.
37. If the clearance is out of tolerance, remove the bearing hub/bearing assembly using a puller.





38. Select and install the new bearing hub/bearing assembly, then recheck.
39. After replacing the bearing hub/bearing assembly, make sure the clearance is within tolerance.
40. Remove the old locknut and old conical spring washer from the countershaft.





41. Install the special tool onto the mainshaft as shown.
42. 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.





43. Install the mainshaft idler gear and the old conical spring washer on the mainshaft. Tighten the old locknut to seat the mainshaft idler gear to 226 Nm (166 ft. lbs.).
44. Install the secondary shaft idler gear and the old conical spring washer on the secondary shaft.
Tighten the old locknut to seat the secondary shaft idler gear to 226 Nm (166 ft. lbs.).

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

45. Remove the old locknuts and old conical spring washers from the mainshaft and secondary shaft.
46. Lubricate the threads of the each shaft, new locknuts, and new conical spring washers with ATF.





47. Install the new conical spring washers in the direction shown, and install the new locknuts.

48. Tighten the locknuts to 167 Nm (123 ft. lbs.).

NOTE:
- Do not use an impact wrench; always use a torque wrench to tighten the locknut.
- Mainshaft locknut has left-hand threads.





49. Stake each locknut into its shaft using a 3.5 mm punch as shown.
50. Set the park lever in the [E position, then verify that the park pawl engages the park gear.
51. If the park pawl does not engage fully, check the distance between the park pawl shaft and the park lever roller pin.





52. Tighten the lock bolt, and bend the lock tab against the lock bolt head.





53. Install the end cover.





54. Set the control shaft in the [N] position by turning it.





55. Set the A/T gear position switch to [N] position.
56. Install the A/T gear position switch on the control shaft, then secure it with the bolts.

NOTE: Take care not to move the A/T gear position switch when tightening the bolts.





57. Install the A/T gear position switch cover, and secure the harness clamp on the end cover with the bolts.
58. Install the ATF cooler lines with new sealing washers.

TORQUE: 28 Nm (21 ft. lbs.)

59. Install the ATF dipstick.