Special Tools Required
Snap ring pliers ( 07LGC-0010100)
| 1. | Install the spacer in the torque converter housing with the spacer tab into the guide of the torque converter housing. Do not install the spacers mix-up in the transmission housing and torque converter housing. Install the differential assembly in the torque converter housing, and put the spacer on the differential.
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| 2. | Drive the differential assembly securely in the torque converter housing so there is no clearance. |
| 3. | Install the 90 mm thrust shim in the transmission housing. |
| 4. | Assemble the mainshaft, countershaft, and secondary shaft.
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| 5. | Join the mainshaft subassembly (A), countershaft subassembly (B), and secondary shaft subassembly (C) together, and install them in the torque converter housing.
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| 6. | Join the countershaft subassembly and secondary shaft subassembly together, then install them in the torque converter housing, and install the mainshaft subassembly. Install the needle bearings, 4th-5th gear, and reverse selector hub over the countershaft. |
| 7. | Turn the shift fork shaft (A) so the large chamfered hole (B) is facing the fork bolt hole (C) of the shift fork (D).
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| 8. | Install the shift fork and reverse selector together on the shift fork shaft and countershaft. Secure the shift fork to the shift fork shaft with the lock bolt and a new lock washer (E), then bend the lock tab of the lock washer against the bolt head. |
| 9. | Install the needle bearing and countershaft reverse gear on the countershaft. |
| 10. | Install the reverse idler gear in the transmission housing. |
| 11. | Install the three dowel pins (A) and a new gasket (B) on the torque converter housing (C).
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| 12. | Align the spring pin (D) of the control shaft (E) with the transmission housing groove (F) by turning the selector control shaft detent plate. Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together, it will causes a faulty shift position signal or position due to the play between the selector control shaft and the switch. |
| 13. | Place the transmission housing (G) on the torque converter housing. Do not install the input shaft (mainshaft) speed sensor and output shaft (countershaft) speed sensor before installing the transmission housing on the torque converter housing. |
| 14. | Wrap a screwdriver tip with tape to prevent damage to the reverse idler gear teeth. Engage the reverse idler gear with reverse gears by rotating the idler gear using the screwdriver.
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| 15. | Install the transmission housing mounting bolts, and tighten the 19 bolts to 44 N·m (4.5 kgf·m, 33 lbf·ft) in two or more steps in a crisscross pattern. |
| 16. | Install the shift solenoid harness connector (E) in the transmission housing with the new O-ring (F).
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| 17. | Connect WHT harnesses and ORN harness connector to shift solenoid valve B. ATF temperature sensor is assembled in the connector with WHT harnesses. |
| 18. | Connect BLU harness connector to shift solenoid valve A, GRN harness connector to shift solenoid valve C, and YEL harness connector to shift solenoid valve D. |
| 19. | Install the shift solenoid valve cover (A), two dowel pins (B), a new gasket (C), and harness clamp bracket (D).
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