Disassembly
Transmission Overhaul
WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.
Special Tool(s)
Material(s)
Exploded View
Disassembly
1. NOTE: Take note of the transmission wiring harness clip locations for installation.
Remove the transmission wiring harness.
2. Remove the 4 TCM (Transmission Control Module) bolts.
3. Using a flat blade screwdriver, carefully pry the TCM (Transmission Control Module) from the transmission, at the location shown, and remove the TCM (Transmission Control Module), discard the O-rings.
4. Remove the 2 TR (Transmission Range) sensor bolts and the TR (Transmission Range) sensor.
5. Remove the OSS (Output Shaft Speed) sensor bolt and OSS (Output Shaft Speed) sensor.
6. Remove the input shaft speed sensor 1.
1. Remove the input shaft speed sensor 1 bolt.
2. Remove the input shaft speed sensor 1.
3. Remove the input shaft speed sensor 1 shim.
7. Remove the input shaft speed sensor 2.
1. Remove the input shaft speed sensor 2 bolt.
2. Remove the input shaft speed sensor 2.
3. Remove the input shaft speed sensor 2 shim.
8. Install the 307-580.
9. Stand the transmission on its back.
10. Remove the 4 clutch motor 1 bolts and remove clutch motor 1.
11. Remove the 4 clutch motor 2 bolts and remove clutch motor 2.
12. Remove and discard the clutch hub snap ring.
13. NOTE: Index mark the clutch hub and clutch for installation.
Remove the clutch hub.
14. Install 307-675 /1 and 307-675 /4.
15. Using 307-675 /1 and 307-675 /4, turn the center bolt of 307-675 /1 with a maximum of 5 Nm (44 lb-in) of torque to push the clutch down to release the pressure from the hollow input shaft snap ring.
16. Remove and discard the hollow input shaft snap ring.
17. NOTE: Make sure the lifting legs are installed on the 3 clutch studs marked with the stamped manufacturing mark as shown.
NOTE: Make sure the lifting leg with the angle is in the location shown.
Install 307-675 /2 and 307-675 /3.
18. Install 307-675 /1.
19. Turn the center bolt of 307-675 /1 with approximately 5 Nm (44 lb-in) of torque until the clutch is free of the input shaft.
20. Using 307-675 /1, 307-675 /2 and 307-675 /3, remove the clutch as an assembly from the transmission.
21. Remove the Z-washers from the engagement system bearing unit.
22. NOTE: The engagement system bearing unit should be removed easily.
Remove the engagement system bearing unit. Inspect for wear or damage. Replace as necessary.
23. NOTICE: Remove the spring retainer bolts by loosening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.
NOTE: The spring retainers and actuator levers are matched sets with corresponding serial numbers. If the spring retainers and actuator levers are being reused, mark on each spring retainer and actuator lever for assembly.
Remove the 4 spring retainer bolts from the spring retainers and remove the spring retainers.
24. Install clutch actuator lever locks as shown if available.
25. Remove the 2 bolts from the clutch actuator lever 1.
26. Remove the 2 bolts from the clutch actuator lever 2.
27. NOTICE: Make sure to properly handle the actuator lever as shown or damage may occur.
Remove the clutch actuator lever 1.
28. NOTICE: Make sure to properly handle the actuator lever as shown or damage may occur.
Remove the clutch actuator lever 2.
29. Remove the guide tube bolts.
30. Remove the guide tube.
31. Using 100-001 (T50T-100-A) and 308-375 , remove and discard the input shaft case seal.
32. Remove and discard the input shaft snap ring.
33. Remove and discard the manual control lever bolt and remove the manual control lever.
34. Remove the top 3 clutch housing-to-case bolts.
35. Remove the bottom 18 clutch housing-to-case bolts (13 shown).
36. Install 307-675 /3.
37. NOTE: Install the 307-675 /1 in the position shown.
Install 307-675 /1 and 307-675 /1 bolts.
- Tighten to 18 Nm (159 lb-in).
38. Turn 307-675 /1 bolt approximately 20 turns to separate the clutch housing from the transmission case.
39. Lift the clutch housing off the transmission case.
40. Remove the differential.
41. Remove the park pawl actuation shaft assembly.
42. Remove the park pawl rod and park pawl.
43. Remove the large clock gears and clock gear pins.
44. Remove the small clock gears and clock gear pins.
45. Remove the magnet.
46. Install 307-680 on the transmission case and gear set assembly.
47. Turn the transmission case and gear set assembly over on 307-680.
48. Remove 307-580 from the transmission case.
49. Remove and discard the 6 output shaft bearing retainer bolts.
50. Lift the transmission case off the gearset assemblies.
51. Remove the park plunger plug.
52. NOTE: Tap the park plunger out towards the inside of the transmission case.
Remove the park plunger.
53. Remove the oil funnel.
54. Remove the 4 shift fork rods.
55. Remove the 2 shift drums.
56. Remove the shift forks and linkages.
57. Install 307-680 /2, 307-680 /4 and 307-680 /5.
58. Turn the gearset assembly over on its side.
59. Remove 307-680 /1.
60. Remove output shaft 1 assembly by removing 307-680 /5.
61. Remove the input shaft assembly by removing 307-680 /4.
62. Remove 307-680 /2 and 307-680 /5 from output shaft 2 assembly.
63. Remove the hollow input shaft from the solid input shaft.
