Part 1
Mainshaft Disassembly, Inspection, and Reassembly1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
Mainshaft:
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, 41 x 68 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Check the clearance of the 5th gear.
Mainshaft 5th Gear Axial Clearance Inspection
'04-06 Models
1. Remove the mainshaft transmission housing bearing.
2. Install 41 x 68 mm thrust washer (A), 4th/5th clutch (B), 4th gear collar (C), and transmission housing bearing (D) on the mainshaft (E). Do not install the O-rings during inspection.
3. Install the idler gear (F) on the mainshaft by a press, then install the conical spring washer (G) and locknut (H).
4. Tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
5. Measure the clearance between the mainshaft flange (A) and 41 x 68 mm thrust washer (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance.
6. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness (A).
7. Select and install a new thrust washer, then recheck.
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.
10. Reinstall the bearing in the transmission housing.
Mainshaft 5th Gear Axial Clearance Inspection
'07 Model
1. Remove the mainshaft transmission housing bearing.
2. Install the thrust needle bearing (A), 5th gear (B), needle bearing (C), thrust needle bearing (D), 41 x 68 mm thrust washer (E), 4th/5th clutch (F), 4th gear collar (G), and transmission housing bearing (H) on the mainshaft (I). Do not install the O-rings during inspection.
3. Install the idler gear (J) on the mainshaft by a press, then install the conical spring washer (K) and locknut (L).
4. Tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
5. Set the dial indicator (A) on the 5th gear (B).
6. Lift the 5th gear (A) up while holding the mainshaft, and use the dial indicator (B) to read the 5th gear axial clearance.
7. Measure the 5th gear axial clearance in at least three places while moving the 5th gear. Use the average as the actual clearance.
Standard: 0.04-0.10 mm (0.002-0.004 in.)
8. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness (A).
9. Select and install a new thrust washer, then recheck.
10. After replacing the thrust washer, make sure the clearance is within the standard.
11. Disassemble the installed parts from the mainshaft.
12. Reinstall the bearing in the transmission housing.
Countershaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
Countershaft:
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, reverse selector, 35 x 47 x 7.8 mm collar, and all gears in the direction shown.
6. Replace the locknut and conical spring washer with new ones when assembling the transmission. The countershaft locknut has left-hand threads.
7. Some reverse selector hubs, and the 3rd gear are press-fitted to the countershaft; special tools are needed to remove them and to install them.
Countershaft Reverse Selector Hub and 3rd Gear Removal
Special Tools Required
Bearing separator 07KAF-PS30200
1. Install the bearing separator on the 4th gear (A). Set a press on the countershaft (B) with putting a spacer (C) between the press and countershaft, and remove the reverse selector hub (D).
NOTE: Some reverse selector hubs are not press-fitted, and can be removed without using the special tool and a press.
2. Remove the needle bearing, set ring, 35 x 47 x 7.8 mm collar, and cotters.
3. Set the press on the countershaft (A) with putting a spacer (B) between the press and countershaft, and remove the 3rd gear (C).
4. Remove the 37 x 41 x 82.8 mm collar, the 5th gear, the 1st gear, and 2nd gear.
Countershaft 3rd Gear and Reverse Selector Hub Installation
Special Tools Required
Driver, 40 mm I.D. 07746-0030100
1. Apply ATF to the parts.
2. Install the 2nd gear, 1st gear, 5th gear, and 37 x 41 x 82.8 mm collar on the countershaft.
3. Slide the 3rd gear (A) over the countershaft, and press it in place with the 40 mm driver and a press.
4. Install the cotters, 35 x 47 x 7.8 mm collar, set ring, needle bearing, and the 4th gear.
5. Slide the reverse selector hub (A) over the countershaft, then press it in place with the 40 mm driver and a press.
NOTE: Some reverse selector hubs are not press-fitted and can be installed without using the 40 mm driver and a press.
Secondary Shaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
Secondary Shaft:
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, idler gear in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the clearance of the 2nd gear and the 1st gear.
Secondary Shaft Ball Bearing, Idler Gear Removal and Installation
Special Tools Required
Attachment, 42 mm I.D. O7QAD-POAO100
Removal
Place a shaft protector (A) on the secondary shaft (B), and set the puller (C) under the idler gear (D), then remove the idler gear and ball bearing (E).
Installation
Install the idler gear (A) on the secondary shaft (B), and install the ball bearing (C) over the idler gear with the 42 mm attachment and a press.
Secondary Shaft 2nd Gear Axial Clearance Inspection
1. Install the thrust needle bearing (A), the needle bearing (B), the 2nd gear (C), the thrust needle bearing (D), the 37 x 58 mm thrust washer (E), and the 2nd clutch (F) on the secondary shaft (G), then secure them with the snap ring (H).
2. Measure the clearance between the snap ring (A) and the 2nd clutch guide (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance.
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer, and measure its thickness.
4. Select and install a new thrust washer, then recheck.
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the shaft and the gears.
Secondary Shaft 1st Gear Axial Clearance Inspection
Special Tools Required
Attachment, 42 mm I.D. 07QAD-P0A0100
1. Install the thrust needle bearing (A), the needle bearing (B), the 1st gear (C), the thrust needle bearing (D), the 40 x 51.5 mm thrust washer (E), the 1st/3rd clutch (F), and the 3rd gear collar (G) on the secondary shaft (H).
2. Install the idler gear (I), then install the ball bearing (J) on the idler gear with the 42 mm attachment and a press.
3. Install the conical spring washer (K) and the locknut (L), then tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
4. Turn the secondary shaft assembly upside down, and set the dial indicator (A) on the 1st gear (B).
5. Hold the secondary shaft, and measure the 1st gear axial clearance in at least three places while moving the 1st gear (A). Use the average as the actual clearance.
6. If the clearance is out of standard, remove the 40 x 51.5 mm thrust washer, and measure its thickness.
7. Select and install a new thrust washer, then recheck.
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and the gears.
Idler Gear Shaft Removal and Installation
1. Remove the snap ring (A), the cotter retainer (B), and the cotter keys (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap rings and the cotter retainer for wear and damage. Replace them if they are worn, distorted, or damaged.
4. Install the idler gear and shaft in the reverse order of removal.
Idler Gear/Idler Gear Shaft Replacement
Special Tools Required
^ Driver 07749-0010000
^ Attachment, 32 x 35 mm 07746-0010100
1. Remove the snap ring from the idler gear/idler shaft assembly.
2. Remove the idler gear shaft (A) from the idler gear (B) with the driver and the 32 x 35 mm attachment and a press.
3. Replace the idler gear or the idler gear shaft, and attach the idler gear shaft to the idler gear.
4. Install the idler gear shaft (A) in the idler gear (B) with the driver and the 32 x 35 mm attachment and a press.
5. Install the snap ring.
Clutch Disassembly
Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
1. Remove the snap ring with a screwdriver.
2. 1st clutch:
Remove the clutch end-plate (A), clutch discs (B) (5), clutch flat-plates (C) (5), and waved spring (D) from the 1st clutch drum (E).
3. '04-05 models 2nd clutch:
Remove the clutch end-plate (A), clutch discs (B) (5), clutch wave-plates (C) (3), 2.0 mm-thick flat-plate (D), 4.0 mm-thick plate (E), and waved spring (F) from the 2nd clutch drum (G).
4. Make a reference mark on 2.0 mm-thick flat-plate.
5. '06-07 models 2nd clutch:
Remove the clutch end-plate (A), clutch discs (B) (6), clutch wave-plates (C) (5), clutch flat-plate (D) (1), and waved spring (E) from the 2nd clutch drum (F).
6. Make reference marks on the clutch wave-plates.
7. '04-05 models 3rd clutch:
Remove the clutch end-plate (A), clutch discs (B) (5), clutch flat-plates (C) (5), and waved spring (D) from the 3rd clutch drum (E).
8. '06-07 models 3rd clutch:
Remove the clutch end-plate (A), clutch discs (B) (6), clutch flat-plates (C) (6), and waved spring (D) from the 3rd clutch drum (E).
9. '04-05 models 4th clutch:
Remove the clutch end-plate (A), clutch discs (B) (4), clutch wave-plates (C) (4), and waved spring (D) from the 4th clutch drum (E).
10. '06-07 models 4th clutch:
Remove the clutch end-plate (A), clutch discs (B) (4), clutch wave-plates (C) (4), and waved spring (D) from the 4th clutch drum (E).
11. '04-05 models 5th clutch:
Remove the clutch end-plate (A), clutch discs (B) (4), clutch wave-plates (C) (4), and waved spring (D) from the 5th clutch drum (E).
12. '06-07 models 5th clutch:
Remove the clutch end-plate (A), clutch discs (B) (4), clutch wave-plates (C) (4), and waved spring (D) from the 5th clutch drum (E).
13. Install the clutch spring compressor.
14. Set the clutch spring compressor (A) on the spring retainer (B) of the 1st, 2nd, and 3rd clutches so the clutch spring compressor works on the clutch return spring (C).
15. Be sure the clutch spring compressor (A) is adjusted to have full contact with the spring retainer (B) on the 4th and 5th clutches.
16. If either end of the clutch spring compressor is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.
17. Compress the return spring until the snap ring can be removed.
18. Remove the snap ring with the snap ring pliers.
19. Remove the clutch spring compressor.
20. Remove the snap ring (A), spring retainer (B), and return spring (C).
21. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other passage while applying air pressure.
22. 1st, 2nd, and 3rd clutches:
Remove the clutch piston (A), remove the O-ring (B) from the piston, and remove the O-ring (C) from the clutch drum (D).
23. 4th and 5th clutches:
Remove the clutch piston (A), and remove the outer O-ring (B) and inner O-ring (C) from the piston.
