Part 3

OIL SEAL INSTALLATION / SIDE CLEARANCE





1. Install a 2.50 mm (0.098 inch) set ring, 80 mm in transmission housing.

NOTE: Do not install the oil seal yet.





2. Install the differential assembly into the torque converter housing using the special tool as shown.
3. Install the transmission housing and tighten the bolts.





4. Tap on the transmission housing side of the differential assembly with the special tool to seat the differential assembly in the torque converter housing.





5. Measure the clearance between the 80 mm set ring and outer race of the ball bearing in the transmission housing.





6. If the clearance is more than the standard, select a new set ring from the table, and install:

NOTE: If the clearance measured in step 5 is standard, it is not necessary to perform steps 7 and 8.

7. Remove the transmission housing.
8. Replace the 2.50 mm (0.098 inch) 80 mm set ring with the one of the correct thickness selected in step 6.





9. Install the new oil seal flush with the transmission housing using the special tools as shown.





10. Install the new oil seal flush with the torque converter housing using the special tools as shown.

TORQUE CONVERTER HOUSING BEARINGS


MAINSHAFT BEARING / OIL SEAL REPLACEMENT





1. Remove the mainshaft bearing and oil seal using the special tools as shown.





2. Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown.





3. Install the new oil seal flush with the housing using the special tools as shown.

COUNTERSHAFT BEARING REPLACEMENT





1. Remove the countershaft bearing using the special tools as shown.
2. Install the ATF guide plate.





3. Drive the new bearing into the housing using the special tools as shown.

TRANSMISSION HOUSING BEARINGS


MAINSHAFT / COUNTERSHAFT BEARINGS REPLACEMENT





1. To remove the mainshaft and countershaft bearings from the transmission housing, expand each snap ring with snap ring pliers, then push the bearing out using the special tools and a press as shown.

NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing.

2. Expand each snap ring with snap ring pliers, insert the new bearing part-way into the housing using the special tools and a press as shown. Install the bearing with the groove facing outside the housing.

NOTE: Coat all parts with Automatic Transmission Fluid (ATF).





3. Release the pliers, then push the bearing down into the housing until the ring snaps in place around it.





4. After installing the bearing verify the following:
- The snap ring is seated in the bearing and housing grooves.
- The ring end gap is correct.

REVERSE IDLER GEAR


INSTALLATION





1. Install the reverse idler gear.





2. Install the reverse idler gear shaft holder and needle bearing into the transmission housing, then tighten the bolts.

PARK STOP


INSPECTION / ADJUSTMENT
1. Set the park lever in the [P] position.





2. Measure the distance between the park pawl shaft and the park lever roller pin as shown.





3. If the measurement is out of tolerance, select and install the appropriate park stop from the table.
4. After replacing the park stop, make sure the distance is within tolerance.

TRANSMISSION REASSEMBLY


REASSEMBLY





NOTE:
- Coat all parts with Automatic Transmission Fluid (ATF).
- The illustration shows the '96-'98 models, the '00 models do not have the servo detent base; the servo detent is integral with the servo body.
- Replace the following parts:
- O-rings
- Lock washers
- Gaskets
- Mainshaft and countershaft locknuts; and conical spring washers
- Sealing washers

1. Install the ATF magnet and suction pipe collar in the torque converter housing, if necessary.
2. Install the main separator plate and the two dowel pins on the torque converter housing.





3. Install the ATF pump drive gear, ATF pump driven gear and ATF pump driven gear shaft on the torque converter housing.

NOTE: Install the ATF pump driven gear with its grooved and chamfered side facing down.

4. Loosely install the main valve body with five 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 directions.
5. Install the secondary valve body, separator plate and two dowel pins on the main valve body.

NOTE: Do not install the bolts.

6. Install the control shaft in the housing with the control shaft and manual valve together.





7. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm.
8. Install the servo body and separator plate on the secondary valve body (eight bolts).
9. Install the servo detent base and the ATF strainer (one bolt).
10. Tighten the five bolts on the main valve body to 12 Nm (8.7 ft. lbs.).
Make sure the ATF pump drive gear and ATF pump driven gear shaft move smoothly.





11. If the ATF pump drive gear and ATF pump driven gear shaft do not move freely, loosen the five bolts on the main valve body, and disassemble the valve bodies.
Realign the ATF pump driven gear shaft and reassemble the valve bodies, then retighten the bolts to the specified torque.

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.

12. Install the stator shaft and stop shaft.
13. Install the bolts and the shaft stop on the secondary valve body, then tighten the bolts (three bolts).
14. Install the torque converter check valve, cooler relief valve and valve springs in the regulator valve body, then install the regulator valve body on the main valve body (one bolt).
15. Install the lock-up valve body on the regulator valve body (seven bolts).
16. Install the ATF feed pipes in the main valve body, the three ATF feed pipes in the secondary valve and the four ATF feed pipes in the servo body.

REASSEMBLY





17. Install the reverse idler gear and the gear shaft holder.
18. Install the differential assembly in the torque converter housing.





19. Assemble the mainshaft sub-assembly and the countershaft sub-assembly, then install them together in the torque converter housing.





20. Turn the shift fork so the large chamfered hole is facing the fork bolt hole, then install the shift fork with the reverse selector, and tighten the lock bolt. Bend the lock tab against the bolt head.
21. Install the needle bearing, countershaft reverse gear and reverse gear collar on the countershaft.





22. Align the spring pin on the control shaft with the transmission housing groove by turning the control shaft.
23. Install the two dowel pins and a new gasket on the torque converter housing.
24. Place the transmission housing on the torque converter housing.

CAUTION: Make sure that the mainshaft speed sensor is not installed on the transmission housing before installing the transmission housing on the torque converter housing.





25. Install the transmission housing mounting bolts along with the transmission hanger, then tighten the bolts in two or more steps in the sequence as shown.





26. Slip the special tool onto the mainshaft as shown.
27. Install the park lever on the control shaft.
28. Assemble the one-way clutch and the park gear with the countershaft 1st gear.





29. Install the countershaft 1st gear collar, needle bearing, and the countershaft 1st gear/park gear assembly on the countershaft.
30. Install the park pawl shaft, spring, pawl, and pawl stop on the transmission housing, then engage the park pawl with the park gear.
31. Install the mainshaft 1st gear collar on the main shaft.
32. Wrap the shaft splines with tape to prevent the O-rings, then install new O-rings on the mainshaft.
33. Assemble the thrust washer, thrust needle bearing, needle bearing, and mainshaft 1st gear in the 1st clutch assembly, then install them on the mainshaft.





34. Install new conical spring washers and locknuts on each shaft.

CAUTION: Install the conical spring washers in the direction shown.

35. Tighten the locknuts to the specified torque.

NOTE:
- Do not use an impact wrench. Always use a torque wrench to tighten the locknut.
- Mainshaft and countershaft locknuts have left hand threads.

TORQUE:
MAINSHAFT: 78 Nm (58 ft. lbs.)
COUNTERSHAFT: 103 Nm (75.9 ft. lbs.)





36. Remove the special tool from mainshaft, then stake each locknut using a 3.5 mm punch as shown.
37. Set the park lever in the [P] position, then verify that the park pawl engages the park gear.
38. If the pawl does not engage fully, check the park pawl stop clearance.





39. Tighten the lock bolt and bend the lock tab.





40. Install the end cover with two dowel pins and a new gasket (thirteen bolts).
41. Install the ATF cooler lines with new sealing washers.

TORQUE: 28 Nm (21 ft. lbs.)





42. Install the ATF dipstick.