Gear Lockout Solenoid: Service and Repair

M/T Reverse Lockout Solenoid Disassembly/Reassembly

1. Turn the ignition switch to LOCK (0), then turn the battery module switch OFF, and measure the voltage at the IMA battery module terminals.

2. Remove the air cleaner Service and Repair.

3. Remove the harness clamp (A), then disconnect the IMA motor power cable connector (B).

NOTE:

- Make sure you have read the IMA system service precautions High Voltage Safety.
- If the IMA motor power cable connector is dirty, clean it before removal.
- Cover the disconnected connector with plastic bag, and wrap the IMA motor power cable terminal with tape.
- If the IMA motor power cable is wet, wait until it is dry.





4. Remove the cable guard bracket (A) and the clutch line bracket (B).






5. Remove the harness bracket (A).





6. Remove the lock pins (B) and the shift cable bracket bolts (C), then carefully remove both cables (D) and the shift cable bracket (E) together out of the way to avoid bending the cables.

7. Disconnect the reverse lockout solenoid 2P connector (F).

8. Disconnect the neutral position switch 2P connector (A), then remove the change lever assembly (B).






9. Remove the three bolts (A) and the reverse lockout solenoid (B).






10. Remove the roller (A), the select lock return spring (B), and the select lock cam (C).





11. Install the components of the reverse lockout solenoid in the reverse order of removal.

12. Clean any dirt and oil from the reverse lockout solenoid sealing surface.





13. Apply liquid gasket (P/N 08718-0001, 08718-0003, or 08718-0004) evenly to the change lever assembly mating surface of the reverse lockout solenoid. Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

14. Install the reverse lockout solenoid (A).






15. Clean any dirt or oil from the change lever assembly sealing surface.





16. Apply liquid gasket (P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009) evenly to the mating surface of the charge lever assembly and the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:

- If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
- If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

17. Install the change lever assembly (A), and connect the neutral position switch 2P connector (B).






18. Connect the reverse lockout solenoid 2P connector (A).





19. Apply a light coat of silicone grease (P/N 08C30-B0234M) to the cable ends (B), and connect the cable ends to the change lever assembly (C), then install the shift cable bracket (D) and the lock pins (E). Do not bend or damage the shift cables.

NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

20. Install the harness bracket (F).

21. Install the cable guard bracket (A) and the clutch line bracket (B).






22. Connect the IMA motor power cable connector (A), then install the harness clamp (B).

NOTE: Make sure you have read the IMA system service precautions High Voltage Safety.





23. Install the air cleaner Service and Repair.

24. Turn the battery module switch ON.

25. Test-drive the vehicle.