Assemble

NOTE:
- Coat all parts with ATF.
- Replace the parts below:
- O-rings
- Lock washers
- Gaskets
- Locknuts Conical spring washer Sealing washers

1. Install the ATF strainer in the torque converter housing.





2. Install the main separator plate with two dowel pins on the torque converter housing. Then install the ATF pump drive gear, driven gear and driven gear shaft.

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

3. Install the main valve body and loosely tighten the 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.
4. Install the secondary valve body, separator plate and two dowel pins on the main valve body.
5. Install the control shaft in the housing, with the control shaft and manual valve together.





6. Install the detent arm and arm shaft in the main valve body, then hook the detent arm, spring to the detent arm.
7. Install the servo body and separator plate (four bolts).
8. Install the modulator valve body, separator plate and two dowel pins (four bolts).
9. Install the accumulator cover (three bolts).
10. Install the servo detent base and baffle plate/suction pipe and new lock washers (three bolts).
11. Install the governor body and new lock washers (three bolts).
12. Tighten the four bolts to 12 Nm (9 ft. lbs.) on the main valve body. Make sure the ATF pump drive gear and ATF pump driven gear shaft move smoothly.





13. If the ATF pump drive gear and ATF pump driven gear shaft do not move freely, loosen the four 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.

14. Install the stator shaft and stop shaft.
15. Install the shaft stop on the secondary valve body (one bolt).
16. Install the regulator valve body (one bolt).
17. Install the torque converter check valve, cooler check valve and valve springs in the regulator valve body.
18. Install the lock-up valve body, separator plate and two dowel pins (seven bolts).
19. Install the ATF feed pipes:
- Two pipes on the servo body
- One pipe on the modulator valve body One pipe on the lock-up valve body
- Two pipes on the main valve body





20. Install the sub-shaft assembly in the transmission housing.
21. Install the reverse idler gear and gear shaft holder.
22. Install the differential assembly in the torque converter housing.

CAUTION: Take care not to damage the governor body.





23. Assembly the mainshaft and countershaft subassembly, then install them together in the torque converter housing.





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





26. Align the spring pin of the control shaft with the transmission housing groove by turning the control shaft.
27. Place the transmission housing on the torque converter housing with a new gasket and the two dowel pins.





28. Install the transmission housing mounting bolts along with the transmission hanger, then torque the bolts in two or more steps in the sequence shown. Torque to 45 Nm (33 ft. lbs.).





29. Install the parking brake lever on the control shaft.
30. Assemble the one-way clutch and the parking gear with the countershaft 1st gear.
31. Install the countershaft 1st gear collar, needle bearing and the countershaft 1st gear/parking gear assembly on the countershaft.
32. Install the parking brake pawl shaft, spring, pawl and pawl stop on the transmission housing, then engage the parking brake pawl with the parking gear.





33. Install the old conical spring washer and locknut on the countershaft. Tighten the old locknut to seat the parking gear to the specified torque, then remove them.

NOTE:
- Do use an impact wrench, always use a torque wrench to tighten the locknut.
- Countershaft locknut has left-hand threads. Torque to 105 Nm (76 ft. lbs.).





34. Slip the special tool onto the mainshaft as shown.
35. Install the sub-shaft 1st gear on the sub-shaft.
36. Install the mainshaft 1st gear collar on the mainshaft.
37. Wrap the mainshaft splines with tape to prevent damage to the O-rings, then install new O-rings on the mainshaft.
38. Install the thrust washer, thrust needle bearing, needle bearing and mainshaft 1st gear in the 1st clutch assembly, then install them on the mainshaft.
39. Install the sub-shaft 1st gear on the sub-shaft, then align the hole of the sub-shaft 1st gear with the hole of the transmission housing. Insert a pin to hold the sub-shaft while tightening the sub-shaft locknut.





40. Install new conical spring washers and new lock nuts on each shaft.

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





41. Tighten the locknuts to their specified torque. Torque:
- Mainshaft to 80 Nm (58 ft. lbs.).
- Countershaft to 105 Nm (76 ft. lbs.).
- Sub-shaft to 95 Nm (69 ft. lbs.).

NOTE:
- Mainshaft and countershaft locknuts have lefthand threads.
- Do not use an impact wrench, always use a torque wrench to tighten the locknuts.

42. Steak each locknut using a 3.5 mm punch.





43. Set the parking brake lever in the P position, then verify that the parking brake pawl engages to the parking gear.
44. If the pawl does not engage fully, check the parking brake pawl stop clearance.
45. Tighten the lock bolt and bend the lock tab.





46. Install the right side cover. Torque to 12 Nm (9 ft. lbs.).
47. Install the throttle control drum with the drum spring on the throttle control shaft. Torque to 8 Nm (6 ft. lbs.).
48. Install the ATF cooler pipes with the joint bolts and new sealing washers. Torque to 29 Nm (21 ft. lbs.).
49. Install the ATF dipstick.