Part 1
ILLUSTRATED INDEXPart 1 Of 2:
Part 2 Of 2:
Transmission End Cover
Part 1 Of 2:
Part 2 Of 2:
Transmission Housing
Torque Converter Housing / Valve Body
RIGHT SIDE COVER
REMOVAL
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the end cover, replace the following:
- O-rings
- Mainshaft and countershaft locknuts
- Conical spring washers
- End cover gasket
- Lock washer
- Sealing washers
1. Remove the 13 bolts securing the end cover, then remove the cover.
2. Slip the special tool onto the mainshaft as shown.
3. Engage the park pawl with the park gear.
4. Cut the lack tabs of the mainshaft and countershaft locknuts using a chisel as shown, then remove the locknuts and conical spring washers.
CAUTION: Keep all of the chiseled particles out of the transmission.
NOTE:
- Mainshaft and countershaft locknuts have left hand threads.
- Always wear safety glasses.
5. Remove the special tool from the mainshaft after removing the locknuts.
6. Remove the 1st clutch and mainshaft 1st gear assembly and mainshaft 1st gear collar from the mainshaft.
7. Remove the park pawl, spring and shaft.
8. Remove the park lever from the control shaft.
9. Using a universal two-jaw puller, remove the park gear, one-way clutch and countershaft 1st gear assembly.
10. Remove the needle bearing and the countershaft 1st gear collar from the countershaft.
11. Remove the Automatic Transmission Fluid (ATF) cooler lines and ATF dipstick.
TRANSMISSION HOUSING
REMOVAL
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the transmission housing, replace the following:
- O-ring
- Transmission housing gasket
- Lock washer
1. Remove the mainshaft speed sensor from the transmission housing.
2. Remove the transmission housing mounting bolts and hanger.
3. Align the spring pin on the control shaft with the transmission housing groove by turning the control shaft.
4. Install the special tool on the transmission housing, then remove the housing as shown.
CAUTION: Make sure the mainshaft speed sensor has been removed from the transmission housing before removing the transmission housing from the torque converter housing.
5. Remove the countershaft reverse gear with the collar and needle bearing,
6. Remove the lock bolt securing the shift fork, then remove the fork with the reverse selector from the countershaft.
7. Remove the countershaft sub-assembly and the mainshaft sub-assembly together.
8. Remove the differential assembly from the torque converter housing.
TORQUE CONVERTER HOUSING / VALVE BODY
REMOVAL
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- When removing the valve body, replace the O-ring.
1. Remove the Automatic Transmission Fluid (ATF) feed pipes from the servo body, secondary valve body and main valve body.
2. Remove the ATF strainer (one bolt).
3. Remove the servo body and servo separator plate eight bolts).
4. Remove the secondary valve body, shaft stop and secondary separator plate (three bolts).
5. Remove the lock-up valve body and separator plate (seven bolts).
6. Remove the regulator valve body (one bolt).
7. Remove the stator shaft and stop shaft.
8. Remove the detent spring from the detent arm, then remove the control shaft from the torque converter housing.
9. Remove the detent arm and detent arm shaft from the main valve body.
10. Remove the main valve body (five bolts).
NOTE: Do not let the eight check balls fall out of the main valve body when removing the main valve body.
11. Remove the ATF pump driven gear shaft, then remove the ATF pump gears.
12. Remove the main separator plate and two dowel pins.
13. Clean the inlet opening of the ATF strainer thoroughly with compressed air, then check that it is in good condition, and the inlet opening is not clogged.
14. Test the filter by pouring clean ATF fluid through the inlet opening. Replace the ATF strainer if it is clogged or damaged.
NOTE: The ATF strainer can be reused if it is not clogged.
VALVE CAPS
DESCRIPTION
- Caps with one projected tip and one flat end are installed with the flat end toward the inside of the valve body.
- Caps with a projected tip on each end are installed with the smaller tip toward the inside of the valve body. The small tip is a spring guide.
- Caps with one projected tip and hollow end are installed with the tip toward the inside of the valve body. The tip is a spring guide.
- Caps with hollow ends are installed with the hollow end away from the inside of the valve body.
- Caps with notched ends are installed with the notch toward the inside of the valve body.
- Caps with flat ends and a hole through the center are installed with the smaller hole toward the inside of the valve body.
- Caps with flat ends and a groove around the cap are installed with the grooved side toward the outside of the valve body.
VALVE BODY
REPAIR
NOTE: This repair is only necessary if one or more of the valves in a valve body do not slide smoothly in their bores. You may use this procedure to free the valves in the valve bodies.
1. Soak a sheet of #600 abrasive paper in Automatic Transmission Fluid (ATF) for about 30 minutes.
2. Carefully tap the valve body so the sticking valve drops out of its bore.
CAUTION: It may be necessary to use a small screwdriver to pry the valve free. Be careful not to scratch the bore with the screwdriver.
3. Inspect the valve for any scuff marks. Use the ATF soaked #600 paper to polish off any burrs that are on the valve, then wash the valve in solvent and dry it with compressed air.
4. Roll up half a sheet of ATF-soaked paper, and insert it in the valve bore of the sticking valve.
Twist the paper slightly, so that it unrolls and fits the bore tightly, then polish the bore by twisting the paper as you push it in and out.
CAUTION: The valve body is aluminum and doesn't require much polishing to remove any burrs.
5. Remove the #600 paper and thoroughly wash the entire valve body in solvent, then dry it with compressed air.
6. Coat the valve with ATF, then drop it into its bore.
It should drop to the bottom of the bore under its own weight. If not, repeat step 4, then retest.
7. Remove the valve, then thoroughly clean it and the valve body with solvent. Dry all parts with compressed air, then reassemble using ATF as a lubricant.
VALVE
ASSEMBLY
NOTE: Coat all parts with Automatic Transmission Fluid (ATF) before assembly.
- Install the valve, valve spring and cap in the valve body and secure with the roller.
- Set the spring in the valve and install it in the valve body. Push the spring in with a screwdriver, then install the spring seat.
- Install the valve, spring and cap in the valve body. Push the cap, then install the clip.
ATF PUMP
INSPECTION
1. Install the Automatic Transmission Fluid (ATF) pump gears and ATF pump driven gear shaft in the main valve body.
NOTE:
- Lubricate all parts with ATF during inspection.
- Install the ATF pump driven gear with its grooved and chamfered side facing up as shown.
2. Measure the side clearance of the ATF pump drive and driven gears.
3. Remove the ATF pump driven gear shaft. Measure the thrust clearance of the ATF pump driven gear-to-valve body.
MAIN VALVE BODY
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
CAUTION: Do not use a magnet to remove the check balls; it may magnetize the balls.
SECONDARY VALVE BODY
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the secondary valve body kit, P/N 27700-P4R-305 (The secondary valve body kit includes the linear solenoid assembly) if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
- The Clutch Pressure Control (CPC) valve is installed in the secondary valve body, held in place by the lock bolt.
REGULATOR VALVE BODY
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
1. Hold the regulator spring cap in place while removing the stop bolt. Once the stop bolt is removed, release the spring cap slowly.
CAUTION: The regulator spring cap can pop out when the stop bolt is removed.
2. Reassembly is the reverse order of the disassembly procedure.
NOTE:
- Coat all parts with ATF during assembly.
- Align the hole in the regulator spring cap with the hole in the valve body, then press the spring cap into the valve body, and tighten the stop bolt.
SERVO BODY
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
- Replace the O-rings.
- The servo body shows the '98 models: the '00 model has integrally molded servo detent.
LOCK-UP VALVE BODY
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.
- Replace the valve body as an assembly if any parts are worn or damaged.
- Check all valves for free movement. If any fail to slide freely, see Valve Body Repair.
- Coat all parts with Automatic Transmission Fluid (ATF) during assembly.
MAINSHAFT
DISASSEMBLY / INSPECTION / REASSEMBLY
NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF) during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the 0-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
- Locknut has left-hand threads.
INSPECTION
- Clearance Measurement
NOTE: Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.
1. Remove the mainshaft bearing from the transmission housing.
2. Assemble the parts on the mainshaft.
NOTE: Do not assemble the O-rings during inspection.
3. Torque the mainshaft locknut to 29 Nm (22 ft. lbs.).
NOTE: Mainshaft locknut has left-hand threads.
4. Hold 2nd gear against the 2nd clutch, then measure the clearance between 2nd gear and 3rd gear with a feeler gauge.
NOTE: Take measurements in at least three places, and use the average as the actual clearance.
STANDARD: 0.05 - 0.13 mm (0.002 - 0.005 inch)
5. If the clearance is out of tolerance, remove the thrust washer and measure the thickness.
6. Select and install a new washer, then recheck.
7. After replacing the thrust washer, make sure the clearance is within tolerance.