Automatic Transmission: Removal & Installation Honda Element I

ATF Replacement

Note. Keep all foreign particles out of the transmission.

Scheme 144

Scheme 145

1. Bring the transmission up to normal operating temperature (the radiator fan comes on).
2. Park the vehicle on level ground, and turn the engine off.
3. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). NOTE: If a cooler cleaner is to be used, refer to ATF cooler cleaning (see «ATF COOLER CLEANING»(ref-220581-S33802604732006022000000) ).
4. Reinstall the drain plug with a new sealing washer (B).
5. Remove the dipstick, and refill the transmission with the recommended fluid amount through the dipstick hole until the level reaches the upper mark on the dipstick. Always use Honda ATF-Z1 Automatic Transmission Fluid (ATF). Using a non-Honda ATF can affect shift quality. Automatic Transmission Fluid Capacity: 4WD model: 3.1 L (3.3 US qt) at change 7.2 L (7.6 US qt) at overhaul 2WD model: 3.2 L (3.4 US qt) at change 6.8 L (7.2 US qt) at overhaul
6. Insert the dipstick (A) back into the transmission with the handle pointing toward the breather pipe (B).

Scheme 146

Scheme 147

1. Raise the vehicle, and make sure it is supported securely.
2. Shift the transmission into the N position.
3. Make a reference mark (A) across the propeller shaft (B) and the transfer companion flange (C).
4. Separate the propeller shaft from the transfer assembly.
5. Set a dial indicator (A) on the transfer companion flange (B), and measure the transfer gear backlash. Standard: 0.06-0.16 mm (0.02-0.06 in.)
6. If the measurement is out of standard, remove the transfer assembly, and adjust the transfer gear backlash (see «TRANSFER ASSEMBLY»(ref-220581-S40283073792006022000000) ).
7. Check for fluid leaks between the mating surfaces of the transfer assembly and transmission.
8. If there is a leak, remove the transfer assembly, and replace the O-ring. Also check for fluid leaks between the mating surfaces of the transfer housing and transfer cover. If there is a leak, remove the transfer cover, and replace the O-ring.
9. Check for leaks between the transfer companion flange and transfer oil seal.
10. If there is a leak, remove the transfer assembly from the transmission, and replace the transfer oil seal and O-ring on the transfer output shaft. If oil seal and O-ring replacement is required, you will need to check and adjust the transfer gear tooth contact, transfer gear backlash, the tapered roller bearing starting torque, and the total starting torque (see «REASSEMBLY»(ref-220581-S38770125172006022000000) ). Do not replace the oil seal with the transfer assembly on the transmission.

Scheme 148

Scheme 149

Scheme 150

1. Raise the vehicle, and make sure it is supported securely.
2. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer (B).
3. Make a reference mark (A) across the propeller shaft (B) and the transfer companion flange (C).
4. Separate the propeller shaft from the transfer assembly.
5. Remove the transfer assembly.

Scheme 151

Scheme 152

1. Clean the area where the transfer assembly contacts the transmission with solvent or carburetor cleaner, and dry with compressed air. Then apply transmission fluid to the contact areas. When installing the transfer assembly, be sure not to allow dust or other foreign particles to enter the transmission.
2. Install the new O-ring (A) on the transfer.
3. Insert the four bolts (B) in the transfer housing, then install the transfer assembly with the dowel pin (C).
4. Install the propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C).
5. Refill the transmission fluid (see step 5 ).
6. Start the engine, and run it to normal operating temperature (the radiator fan comes on). Turn the engine off, and check the fluid level (see «ATF LEVEL CHECK»(ref-220581-S17712182262006022000000) ).

Transmission Removal

Special Tools Required

1. Engine hanger adapter VSB02C000015
2. Engine support hanger, A and Reds AAR-T-12566
3. Front subframe adapter VSB02C000016 (Available through the Honda Tool and Equipment Program 1-888-424-6857)

Note. Use fender covers to avoid damaging pained surfaces.

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

1. Before disconnecting the battery, make sure you have the anti-theft code for the radio, then write down the audio preset.
2. Raise the vehicle, and make sure it is securely supported.
3. Remove the splash shield.
4. Remove the drain plug (A), and drain the automatic transmission fluid (ATF). Reinstall the drain plug with a new sealing washer (B).
5. Disconnect the battery negative terminal, then disconnect the battery positive terminal.
6. Remove the air cleaner housing and the air intake duct.
7. Remove the battery hold-down bracket, then remove the battery and battery tray.
8. Remove the harness clamp from the battery base, then remove the battery base.
9. Remove the transmission ground terminal (A).
10. Disconnect the 2nd clutch transmission fluid pressure switch connector (B) and A/T clutch pressure control solenoid valve A connector (C), and remove the harness clamps (D) from the clamp brackets (E).
11. Disconnect the output shaft (countershaft) speed sensor connector (A) and input shaft (mainshaft) speed sensor (B).
12. Remove the transmission range switch connector (C) from its bracket (D), then disconnect it.
13. Disconnect the 3rd clutch transmission fluid pressure switch connector.
14. Disconnect the shift solenoid harness connector (A), A/T clutch pressure control solenoid valve B connector, and solenoid valve C connector, then remove the harness clamps (D) from the clamp brackets (E).
15. Remove the ATF cooler hoses (A) from the ATF cooler lines (B). Turn the ends of the ATF cooler hoses up to prevent ATF from flowing out, then plug the ATF cooler hoses and lines.
16. Check for any signs of leakage at the hose joints.
17. Remove the harness clamp (A) from the clamp bracket (B), and remove the engine wire harness cover (C) from its bracket (D).
18. Remove the bolts (A) securing the water line and harness brackets (B).
19. Attach the special tool adapter (VSB02C000015) to the threaded hole (A) in the cylinder head.
20. Install the engine support hanger (AAR-T-12566) to the vehicle, and attach the hook (A) to the special tool adapter (VSB02C000015). Tighten the wing nut (B) by hand, and lift and support the engine.
21. Insert a 5 mm hex wrench (A) in the top of the ball joint pin (B), and remove the nut (C), then separate the stabilizer link (D) from the lower arm.
22. Remove the lock pin (E) and castle nuts (F). Install the ball joint thread protector (07AAF-SDAA100) on the ball joint threads, and separate the lower arms (G) from the knuckles (H) (see step 10 on «KNUCKLE AND HUB REPLACEMENT»(ref-220587-S21429159382006022000000) ).
23. Remove the torque converter cover (A), and remove the eight drive plate bolts (B) while rotating the crankshaft pulley.
24. 4WD model: Remove the shift cable. 1 Remove the bolts (A) securing the shift cable bracket (B), then remove the shift cable cover (C). 2 Remove the spring clip (D) and control pin (E), then separate the shift cable (F) from the selector control lever (G). Do not bend the shift cable excessively. 3 Remove the bolts (H) securing the shift cable bracket (I), then remove the shift cable bracket (I) from the shift cable.
25. 2WD model: Remove the shift cable. 1 Remove the shift cable cover (A). 2 Remove the spring clip (B) and control pin (C), then separate the shift cable (D) from the selector control lever (E). 3 Remove the bolts securing the shift cable bracket (F). Do not bend the shift cable excessively.
26. Disconnect the ATF cooler hose (A) from the ATF cooler line (B), then plug the end of the hose.
27. Remove the front mount bolt (C) and nut (D).
28. Remove the rear mount bolts.
29. Make the appropriate reference lines at positions A and B that line up with the center of the subframe mounting bolts (C).
30. Attach the special tool to the subframe with hanging the hook of the special tool over the front of the subframe, then tighten the special tool screw.
31. Raise the jack and line up the slots in the arms with the bolt holes on the corner of the jack base, then attach them with the bolts securely.
32. Remove the four subframe mounting bolts, then lower the subframe.
33. 4WD model: Make a reference mark (A) across the propeller shaft (B) and the transfer companion flange (C), then separate the propeller shaft from the transfer assembly.
34. Pry the left driveshaft out of the differential (see step 9 on «FRONT DRIVESHAFT REMOVAL»(ref-220583-S37471675282006022000000) ).
35. Remove the driveshafts from the differential and intermediate shaft.
36. Remove the intermediate shaft cover (A).
37. Remove the intermediate shaft (B). Coat all precision finished surfaces with clean engine oil, then tie plastic bags over the driveshaft and intermediate shaft ends.
38. Place a jack under the transmission.
39. Remove the transmission housing upper mounting bolts.
40. Remove the transmission mount bracket bolt (A) and nuts (B), then remove the transmission mount bolt (C).
41. Remove the transmission housing front mounting bolts located on front lower of the transmission.
42. Remove the transmission housing rear mounting bolts located on the rear lower of the transmission.
43. Slide the transmission away from the engine to remove it from the vehicle.
44. Remove the torque converter assembly.
45. Remove the front mount.
46. Remove the rear mount/bracket. NOTE: The illustration shows 4WD model; 2WD model is similar.
47. Remove the air cleaner housing mounting bracket.
48. Inspect the drive plate, and replace it if it's damaged.

Scheme 183

1. Remove the transmission assembly (see «TRANSMISSION REMOVAL»(ref-220581-S19276339322006022000000) ).
2. Remove the drive plate (A) and washer (B) from the engine crankshaft.
3. Install the drive plate and washer on the engine crankshaft, and tighten the eight bolts in a crisscross pattern in two or more steps.
4. Install the transmission assembly (see «TRANSMISSION INSTALLATION»(ref-220581-S09486074762006022000000) ).

Transmission Installation

Special Tools Required

1. Engine hanger adapter VSB02C000015
2. Engine support hanger, A and Reds AAR-T-12566
3. Front subframe adapter VSB02C000016 (Available through the Honda Tool and Equipment Program 1-888-424-6857)

Note. Use fender covers to avoid damaging pained surfaces.

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

1. Clean the ATF cooler (see «ATF COOLER CLEANING»(ref-220581-S33802604732006022000000) ).
2. Install the air cleaner housing mounting bracket.
3. Install the front mount.
4. Install the rear mount/bracket. NOTE: The illustration shows 4WD model; 2WD model is similar.
5. Install the torque converter assembly (A) on the mainshaft (B) with the new O-ring (C).
6. Install the 14 x 20 mm dowel pins (D) in the torque converter housing.
7. Place the transmission on a jack, and raise the transmission to the engine level.
8. Attach the transmission to the engine, then install the transmission housing rear mounting bolts.
9. Install the transmission housing front mounting bolts.
10. Install the transmission housing upper mounting bolts.
11. Install the transmission mount bracket. Tighten the mount bolt (A) loosely, and tighten the transmission mount bracket bolt and nuts to the specified torque, then tighten the mount bolt to the specified torque.
12. Install the new set ring (A) on the intermediate shaft (B).
13. Clean the areas where the intermediate shaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Then install the intermediate shaft in the differential. While installing the intermediate shaft, be sure not to allow dust or other foreign particles to enter the transmission.
14. Install the intermediate shaft cover (C), but do not tighten the bolts.
15. Tighten the upper right bolt (D) on the cover first, then lower right bolt (E), and lastly the left bolt (F).
16. Install the new set ring (A) on the left driveshaft (B).
17. Install the right and left driveshaft (see «FRONT DRIVESHAFT INSTALLATION»(ref-220583-S40013403662006022000000) ). While installing the left driveshaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission. NOTE: Clean the areas where the left driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Turn the right and left steering knuckle fully outward, and slide the left driveshaft into the differential until you feel its set ring engage the side gear. Slide the right driveshaft over the intermediate shaft splines until you feel the driveshaft engage the intermediate shaft set ring.
18. Install the propeller shaft (A) to the transfer companion flange (B) by aligning the reference mark (C).
19. Support the subframe with the special tool and a jack, and lift it up to body.
20. Loosely install the new subframe mounting bolts.
21. Align the reference marks (A) with the center of the subframe mounting bolts (B), then tighten the bolts to the specified torque.
22. Install the rear mount bolts.
23. Install the front mount bolt (A) and nut (B), connect the ATF cooler hose (C) to the ATF cooler line, then secure the hose with the clip (see «ATF COOLER HOSE REPLACEMENT»(ref-220581-S12329737862006022000000) ).
24. 4WD model: Install the shift cable. 1 Face the dot (A) on the shift cable (B) down, then install the shift cable bracket (C) on the shift cable. 2 Attach the shift cable end (D) to the selector control lever (E), then insert the control pin (F) into the selector control lever hole through the shift cable end. 3 Secure the control pin with the spring clip (G). Do not bend the shift cable excessively. 4 Secure the shift cable bracket (H) with the bolts, and install the shift cable cover (I), but do not tighten the bolts. 5 Tighten the front bolt (J) on the cover first, then the lower bolt (K), and lastly the middle bolt (L).
25. 2WD model: Install the shift cable. 1 Attach the shift cable end (A) to the selector control lever (B), then insert the control pin (C) into the selector control lever hole through the shift cable end, and secure the control pin with the spring clip (D). Do not bend the shift cable excessively. 2 Secure the shift cable bracket (E) with the bolt, and install the shift cable cover (F), but do not tighten the bolts. 3 Tighten the front bolt (G) on the cover first, then the lower bolt (H), and lastly the middle bolt (I).
26. Attach the torque converter to the drive plate with eight bolts (A). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates freely.
27. Install the torque converter cover (B).
28. Connect the ball joints (A) to the lower arms (B), and install the castle nuts (C) and lock pins (D). Keep the ball joint threads free of grease. Install the spring clips from the inside of the vehicle, with their hooked sides facing the front (E) of the vehicle in the direction shown.
29. Connect the ball joints (F) to the lower arms, and install the nuts (G). Insert a 5 mm hex wrench (H) in the top of the ball joint pins, and tighten the nuts.
30. Remove the engine support hanger, and remove the special tool adapter from the engine.
31. Install the removed bolts and the water line and harness bracket.
32. Connect the ATF cooler hoses (A) to the ATF cooler lines (B) (see «ATF COOLER HOSE REPLACEMENT»(ref-220581-S12329737862006022000000) ).
33. Connect the shift solenoid harness connector (A), A/T clutch pressure control solenoid valve B connector, and solenoid valve C connector. Install the harness clamps (D) on the clamp brackets (E).
34. Connect the 3rd clutch transmission fluid pressure switch connector.
35. Install the engine wire harness cover (A) on its bracket (B), and install the harness clamp (C) on the bracket (D).
36. Connect the transmission range switch connector (A), and install it on its bracket (B).
37. Connect the connectors to the input shaft (mainshaft) speed sensor (C) and output shaft (countershaft) speed sensor (D).
38. Connect the A/T clutch pressure control solenoid valve A connector and 2nd clutch transmission fluid pressure switch connector (B), and install the harness clamps (C) on the clamp brackets (D).
39. Install the transmission ground terminal (E).
40. Install the battery base, then install the harness clamp on the clamp bracket on the base.
41. Refill the transmission with ATF (see step 5 ).
42. Install the air intake duct and air cleaner housing.
43. Install the battery tray and battery, then secure the battery with its hold-down bracket.
44. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
45. Set the parking brake. Start the engine, and shift the transmission through all gears three times.
46. Check the shift lever operation, A/T gear position indicator operation, and shift cable adjustment.
47. Check and adjust the front wheel alignment (see «WHEEL ALIGNMENT»(ref-220585-S33787417282006022000000) ).
48. Install the splash shield.
49. Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fan comes on).
50. Turn off the engine, and check the ATF level (see «ATF LEVEL CHECK»(ref-220581-S17712182262006022000000) ).
51. Do the power window control unit reset procedure (see «RESETTING THE POWER WINDOW CONTROL UNIT»(ref-220630-S35739607722006022100000) ).
52. Perform the road test (see «ROAD TEST»(ref-220581-S16084978032006022000000) ).
53. Loosen the bolts of the front mount, rear mount, and transmission mount after the road test.
54. Tighten the transmission mount bolt to 54 N.m (5.5 kgf.m, 40 lbf.ft), tighten the rear mount bolt to 64 N.m (6.5 kgf.m, 47 lbf.ft), and lastly tighten the front mount bolt to 64 N.m (6.5 kgf.m, 47 lbf.ft).
55. Enter the anti-theft code for the radio, then enter the audio presets, and set the clock.

Idler Gear Shaft Bearing Replacement

Special Tools Required

1. Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
2. Driver 07749-0010000
3. Attachment, 52 x 55 mm 07746-0010400

Scheme 212

Scheme 213

1. Remove the idler gear shaft bearing (A) from the end cover (B) with the special tool and commercially available 3/8 "-16 slide hammer (C).
2. Install the new bearing in the end cover with the special tools.

Selector Control Shaft Oil Seal Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 22 x 24 mm 07746-0010800

Scheme 214

Scheme 215

1. Remove the oil seal (A) from the end cover (B).
2. Install the new oil seal flush to the end cover with the special tools.

Selector Control Shaft Bearing Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 22 x 24 mm 07746-0010800

Scheme 216

Scheme 217

1. Remove the oil seal from the end cover, then remove the bearing.
2. Install the new bearing flush to the end cover with the special tools.
3. Install the new oil seal (see «IDLER GEAR SHAFT BEARING REPLACEMENT»(ref-220581-S02364757142006022000000) )

Scheme 218

1. Remove the snap rings (A), ATF feed pipes (B), and feed pipe flanges (C) from the end cover (D).
2. Install the new O-rings (E) over the ATF feed pipes.
3. Install the ATF feed pipes in the end cover by aligning the feed pipe tabs with the indentations in the end cover.
4. Install the new O-rings (F) in the end cover, then install the feed pipe flanges over the ATF feed pipes and O-rings.
5. Secure the ATF feed pipes and feed pipe flanges with the snap ring.

Scheme 219

Scheme 220

Special Tools Required

Housing puller 07HAC-PK40102

Note. Refer to the EXPLODED VIEW as needed during the following procedure.

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

1. Remove the ATF feed pipe from the idler gear shaft, and the ATF lubrication pipe from the transmission housing.
2. Remove the shift solenoid valve cover (A), dowel pins (B), and gasket (C).
3. Remove the bolt (A) securing the solenoid harness connector (B), and remove the connector.
4. Disconnect the connectors from the shift solenoid valves.
5. Remove the input shaft (mainshaft) and output shaft (countershaft) speed sensors.
6. Remove the transmission housing mounting bolts, transmission hanger, and harness clamp brackets.
7. Align the spring pin (A) on the selector control shaft (B) with the transmission housing groove (C) by turning the selector control shaft. NOTE: Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together it could cause a faulty signal or position due to the play between the selector control shaft and the switch.
8. While expanding the snap ring of the secondary shaft bearing using the snap ring pliers, lift the transmission housing. Release the snap ring pliers, and remove the transmission housing.
9. Remove the countershaft reverse gear and needle bearing.
10. Remove the lock bolt securing the shift fork, then remove the shift fork with the reverse selector together.
11. Remove the selector control lever from the selector control shaft.
12. Unhook the detent spring (A) from the detent arm (B).
13. Remove the selector control shaft (A).
14. Turn the detent arm (B) away from the countershaft (C).
15. Remove the mainshaft subassembly (A), countershaft subassembly (B), and secondary shaft subassembly (C) together.
16. Remove the differential assembly.
17. 2005-2006 models: Remove the baffle plate.
18. 4WD model: Remove the transfer assembly.

Bearing Removal

Special Tools Required

1. Attachment, 78 x 90 mm 07GAD-SD40101
2. Driver 07749-0010000
3. Attachment, 42 x 47 mm 07746-0010300

Scheme 227

Scheme 228

1. Remove the idler gear shaft when removing the mainshaft bearing and idler gear shaft bearing. NOTE: If you are only removing the countershaft bearing, idler gear shaft removal is not needed.
2. To remove the mainshaft bearing (A) and countershaft bearing (B) from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out. NOTE: Do not remove the snap ring unless it's necessary to clean the grooves in the housing.
3. Expand the snap ring of the idler gear shaft bearing with the snap ring pliers, then push the bearing out.

Bearing Installation

Special Tools Required

1. Attachment, 78 x 90 mm 07GAD-SD40101
2. Driver 07749-0010000
3. Attachment, 42 x 47 mm 07746-0010300

Scheme 229

Scheme 230

Scheme 231

1. Install the bearings in the direction shown.
2. Expand each snap ring with the snap ring pliers, and install the mainshaft bearing (A) and countershaft bearing (B) part-way into the housing.
3. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
4. Expand the snap ring of the idler gear shaft (A) with the snap ring pliers, and install the bearing partway into the housing.
5. Release the pliers, then push the bearing down into the housing until the snap ring snaps in place around it.
6. After installing the bearings verify that the snap rings (A) are seated in the bearing and housing grooves, and that the ring end gaps (B) are correct.
7. Install the idler shaft.

Scheme 232

Scheme 233

1. Remove the bolt (A) securing the reverse idler gear shaft holder.
2. Install a 5 x 0.8 mm bolt (B) in the reverse idler gear shaft, and pull it to remove the reverse idler gear shaft (C) and gear shaft holder (D) together.
3. Remove the reverse idler gear.

Scheme 234

Scheme 235

1. Install the reverse idler gear in the transmission housing.
2. Lightly coat the reverse idler gear shaft (A), needle bearing (B), and new O-rings (C) with lithium grease.
3. Assemble the new O-rings and needle bearing on the reverse idler gear shaft, then install the reverse idler gear shaft in the reverse idler gear shaft holder (D). Align the D-shaped cut out (E) of the shaft with the D-shaped area (F) of the holder.
4. Install the reverse idler gear shaft/holder assembly on the transmission housing.

Shift Solenoid Valve Installation

Note. Do not install shift solenoid valve B before installing shift solenoid valve E. If solenoid valve B is installed before solenoid valve E, it may damage the hydraulic control system. Do not hold the shift solenoid valve connector to install it. Be sure to hold the shift solenoid valve body.

Scheme 236

1. Install new O-rings (F) on each shift solenoid valve. NOTE: The new shift solenoid valve is equipped with new O-rings. If you install a new shift solenoid valve, there is no need to replace its O-rings.
2. Install shift solenoid valve A by holding the shift solenoid valve body; be sure the mounting bracket contacts the servo body.
3. Install shift solenoid valve E by holding the shift solenoid valve body; be sure the mounting bracket contacts the servo body.
4. Install shift solenoid valve B by holding the shift solenoid valve body; be sure the mounting bracket contacts the bracket on shift solenoid valve E.
5. Install shift solenoid valve C by holding the shift solenoid valve body; be sure the mounting bracket contacts the servo body.

Mainshaft Bearing and Oil Seal Replacement

Special Tools Required

1. Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
2. Driver 07749-0010000
3. Attachment, 62 x 68 mm 07746-0010500
4. Attachment, 72 x 75 mm 07746-0010600

Scheme 237

Scheme 238

Scheme 239

1. Remove the mainshaft bearing and oil seal with the special tool and a commercially available 3/8"-16 slide hammer (A).
2. Install the new mainshaft bearing until it bottoms in the torque converter housing with the special tools.
3. Install the new oil seal flush in the torque converter housing with the special tools.

Countershaft Bearing Replacement

Special Tools Required

1. Adjustable bearing puller, 25-40 mm 07736-A01000B or 07736-A01000A
2. Driver 07749-0010000
3. Attachment, 62 x 68 mm 07746-0010500

Scheme 240

Scheme 241

1. Remove the countershaft bearing with the special tool and a commercially available 3/8"-16 slide hammer (A).
2. Install the ATF guide plate (A).
3. Install the new countershaft bearing (B) in the housing with the special tools.

Secondary Shaft Bearing Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 62 x 68 mm 07746-0010500

Scheme 242

Scheme 243

Scheme 244

Scheme 245

1. Remove the bolt, then remove the lock washer (A) and bearing set plate (B).
2. Remove the secondary shaft bearing (A) by heating the housing to about 212°F (100°C) with a heat gun (B). Do not heat the housing in excess of 212°F (100°C). NOTE: Let the housing cool to normal temperature before installing the bearing.
3. Install the new O-rings (A) on the ATF guide collar (B), then install the ATF guide collar in the housing.
4. Install the new secondary shaft bearing (C) in the direction shown.
5. Drive the secondary shaft bearing with the special tools, and install it securely in the housing.
6. Check that the bearing groove aligns with the housing surface, then install the bearing set plate with aligning the bearing groove.
7. Install the new lock washer and bolt, then bend the lock tab of the lock washer against the bolt head.

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 22 x 24 mm 07746-0010800

Scheme 246

Scheme 247

1. Remove the oil seal (A) from the torque converter housing (B).
2. Install the new oil seal flush to the torque converter housing with the special tools.

Scheme 248

1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and 41 x 68 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Check the clearance of the 3rd gear.

Scheme 249

Scheme 250

Scheme 251

1. Remove the mainshaft transmission housing bearing (see «BEARING REMOVAL»(ref-220581-S15645469232006022000000) ).
2. Assemble the 41 x 68 mm thrust washer (A), 3rd/4th clutch (B), 4th gear collar (C), and the transmission housing bearing (D) on the mainshaft (E). Do not install the O-rings during inspection.
3. Install the idler gear (F) on the mainshaft with a press, then install the conical spring washer (G) and locknut (H).
4. Tighten the locknut to 29 N.m (3.0 kgf.m, 22 lbf.ft).
5. Measure the clearance between the mainshaft flange (A) and 41 x 68 mm thrust washer (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance. Standard: 0.03-0.31 mm (0.001-0.012 in.)
6. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness.
7. Select and install a new thrust washer, then recheck. THRUST WASHER, 41 x 68 mm THRUST WASHER, 41 x 68 mm No. Part Number Thickness 1 90414-PRP-010 6.35 mm (0.250 in.) 2 90415-PRP-010 6.40 mm (0.252 in.) 3 90416-PRP-010 6.45 mm (0.254 in.) 4 90417-PRP-010 6.50 mm (0.256 in.) 5 90418-PRP-010 6.55 mm (0.258 in.) 6 90419-PRP-010 6.60 mm (0.260 in.)
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.
10. Reinstall the bearing in the transmission housing (see «BEARING INSTALLATION»(ref-220581-S08588600692006022000000) ).

Scheme 252

1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, reverse selector, 35 x 47 x 7.8 mm collar, 3rd gear, 1st gear, and 2nd gear in the direction shown.
6. Replace the locknut and conical spring washer with new ones when assembling the transmission. The countershaft locknut has left-hand threads.
7. Some reverse selector hubs are press-fitted to the countershaft; special tools are needed to remove them (see «COUNTERSHAFT REVERSE SELECTOR HUB REMOVAL»(ref-220581-S28444475172006022000000) ) and to install them (see «COUNTERSHAFT REVERSE SELECTOR HUB INSTALLATION»(ref-220581-S22969282262006022000000) ).

Scheme 253

1. Remove the reverse selector hub (A) and the 4th gear (B) from the countershaft with a press. Place a shaft protector (C) between the countershaft and press to prevent damaging the countershaft. NOTE: Some reverse selector hubs are not press-fitted and can be removed without using a press.
2. Remove the needle bearing, set ring, 35 x 47 x 7.8 mm collar, 31 mm cotters, and 37 x 41 x 82.8 mm collar from the countershaft.
3. Remove 1st, 3rd, and 2nd gears from the countershaft by hand.

Countershaft Reverse Selector Hub Installation

Special Tools Required

Driver, 40 mm I.D. 07746-0030100

Scheme 254

1. Apply ATF to the parts.
2. Install 2nd, 1st, and 3rd gears on the countershaft by hand.
3. Install the 37 x 41 x 82.8 mm collar, 31 mm cotters, 35 x 47 x 7.8 mm collar, set ring needle bearing, and 4th gear on the countershaft.
4. Slide the reverse selector hub (A) over the countershaft (B), then press it in place with the special tool and a press. NOTE: Some reverse selector hubs are not press-fitted and can be installed without using the special tool and a press.

Scheme 255

1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surfaces for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and idler gear in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission. The secondary shaft locknut has left-hand threads.
8. Check the clearance of 2nd and 1st gears.

Secondary Shaft Ball Bearing, Idler Gear Removal and Installation

Special Tools Required

Attachment, 42 mm I.D. 07QAD-P0A0100

Removal

Place a shaft protector (A) on the secondary shaft (B), place the puller (C) on the idler gear (D), then remove the idler gear and ball bearing (E).

Scheme 256

Installation

Install the idler gear (A) on the secondary shaft (B), and install the ball bearing (C) on the shaft with the special tool and a press.

Scheme 257

Scheme 258

Scheme 259

1. Install the thrust needle bearing (A), needle bearing (B), 2nd gear (C), thrust needle bearing (D), 37 x 58 mm thrust washer (E), and 2nd clutch (F) on the secondary shaft (G), then secure them with the snap ring (H).
2. Measure the clearance between the snap ring (A) and the 2nd clutch guide (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance. Standard: 0.04-0.12 mm (0.002-0.005 in.)
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer and measure its thickness.
4. Select and install a new thrust washer, then recheck. THRUST WASHER, 37 x 58 mm THRUST WASHER, 37 x 58 mm No. Part Number Thickness 1 90511-PRP-010 3.900 mm (0.154 in.) 2 90512-PRP-010 3.925 mm (0.155 in.) 3 90513-PRP-010 3.950 mm (0.156 in.) 4 90514-PRP-010 3.975 mm (0.156 in.) 5 90515-PRP-010 4.000 mm (0.157 in.) 6 90516-PRP-010 4.025 mm (0.158 in.) 7 90517-PRP-010 4.050 mm (0.159 in.) 8 90518-PRP-010 4.075 mm (0.160 in.) 9 90519-PRP-010 4.100 mm (0.161 in.) 10 90520-PRP-010 4.125 mm (0.162 in.) 11 90521-PRP-010 4.150 mm (0.163 in.) 12 90522-PRP-010 4.175 mm (0.164 in.) 13 90523-PRP-000 4.200 mm (0.165 in.) 14 90524-PRP-000 4.225 mm (0.166 in.) 15 90525-PRP-000 4.250 mm (0.167 in.) 16 90526-PRP-000 4.275 mm (0.168 in.) 17 90527-PRP-000 4.300 mm (0.169 in.) 18 90528-PRP-000 4.325 mm (0.170 in.) 19 90529-PRP-000 4.350 mm (0.171 in.) 20 90530-PRP-000 4.375 mm (0.172 in.)
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the shaft and gears.

Idler Gear/Idler Gear Shaft Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 32 x 35 mm 07746-0010100

Scheme 260

Scheme 261

Scheme 262

Scheme 263

1. Remove the snap ring from the idler gear/idler shaft assembly.
2. Remove the idler gear shaft (A) from the idler gear (B) with the special tools and a press.
3. Replace the idler gear or idler gear shaft, and attach the idler gear shaft to the idler gear.
4. Install the idler gear shaft (A) in the idler gear (B) with the special tools and a press.
5. Install the snap ring.

End Cover Installation

Special Tools Required

Mainshaft holder 07GAB-PF50101 or 07GAB-PF50100

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

1. Install the special tool onto the mainshaft.
2. Lubricate the following parts with ATF: Splines and threads of the mainshaft. Splines of the mainshaft idler gear. Old conical spring washer and old locknut.
3. Install the mainshaft idler gear (A), old conical spring washer (B), and old locknut (C) on the mainshaft (D), and tighten the locknut to 226 N.m (23.0 kgf.m, 166 lbf.ft). NOTE: Do not tap the idler gear to install. Use a torque wrench to tighten the locknut. Do not use an impact wrench.
4. Install the park lever (A) and park lever stop (B) on the selector control shaft (C), then install the lock bolt with the new lock washer (D). Do not bend the lock tab of the lock washer until step 18 .
5. Install the park pawl shaft (E), park pawl spring (F), park pawl (G), and stop shaft (H) on the transmission housing.
6. Lubricate the following parts with ATF: Threads and splines of the countershaft. Old conical spring washer and old locknut. Areas where the park gear contacts the conical spring washer.
7. Install the park gear (I), old conical spring washer (J), and old locknut (K) on the countershaft.
8. Lift the park pawl up, and engage it with the park gear, then tighten the locknut to 226 N.m (23.0 kgf.m, 166 lbf.ft). NOTE: Do not tap the park gear to install. Use a torque wrench to tighten the locknut. Do not use an impact wrench. Countershaft locknut has left-hand threads.
9. Remove the locknuts and conical spring washers from the mainshaft and countershaft.
10. Lubricate the threads of the shafts, the new locknuts, and the new conical spring washers with ATF.
11. Install the new conical spring washers (A) in the direction shown, and install the new mainshaft locknut (B), the new countershaft locknut (C), and the new secondary shaft locknut (D).
12. Tighten the locknuts to 167 N.m (17.0 kgf.m, 123 lbf.ft). NOTE: Be sure to install the conical spring washers in the direction shown. Use a torque wrench to tighten the locknut. Do not use an impact wrench. Countershaft and secondary shaft locknuts have left-hand threads.
13. Remove the special tool from the mainshaft.
14. Stake the locknuts into the shafts with a punch.
15. Install the selector control lever (A) on the selector control shaft (B), and install the bolt with the new lock washer (C), then bend the lock tab of the lock washer against the bolt head.
16. Set the park lever in the P position, then verify that the park pawl (A) engages the park gear (B).
17. If the park pawl does not engage fully, check the distance (C) between the pawl shaft (D) and the park lever roller pin (E) (see «PARK LEVER STOP INSPECTION AND ADJUSTMENT»(ref-220581-S01554454522006022000000) ).
18. Tighten the lock bolt, and bend the lock tab of the lock washer (F) against the bolt head.
19. Install the ATF feed pipe (A) into the idler gear shaft, and install the ATF lubrication pipe (B) into the transmission housing.
20. Install the end cover (A) with the two dowel pins, new O-rings, and new gasket. Tighten the 6 x 1.0 mm bolts (12) (B) and 8 x 1.0 mm bolts (3) (C).
21. Install the harness clamp bracket (D) on the end cover.
22. Set the selector control shaft (A) to the N position by turning the selector control lever on the torque converter side. NOTE: Do not squeeze the end of the selector control shaft tips together when turning the shaft. If the tips are squeezed together when turning the shaft. If the tips are squeezed together, it will cause a faulty shift position signal or position due to the play between the selector control shaft and the switch.
23. Align the cutouts (A) on the rotary-frame with the neutral positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.08 in.) feeler gauge blade (D) in the cutouts to hold in the N position. NOTE: Be sure to use a 2.0 mm (0.08 in.) blade or equivalent to hold the switch in the N position.
24. Install the transmission range switch (A) gently on the selector control shaft (B) while holding the N position with the 2.0 mm (0.08 in.) blade (C).
25. Tighten the bolts on the transmission range switch while you continue to hold the N position. Do not move the transmission range switch when tightening the bolts. Remove the feeler gauge.
26. Connect the transmission range switch connector (A) securely, then install the harness clamps (B) on the clamp bracket (C).
27. Install the transmission range switch cover (D).
28. Install the new gasket (B) on the transmission housing, and install the ATF pipe (C) and ATF joint pipes (D).
29. Install the new O-rings (E) over the ATF joint pipes.
30. Install A/T clutch pressure control solenoid valve A.
31. Install the new gasket (A) on the transmission housing, and install the ATF joint pipes (D).
32. Install the new O-rings (E) over the ATF joint pipes.
33. Install A/T clutch pressure control solenoid valves B and C and harness clamp brackets (F).
34. Install the ATF cooler inlet line (A) with the new sealing washers (B), and install the bracket (C) of the ATF cooler inlet line on the shift solenoid valve cover hole (D) (see step 23 ).
35. Install the ATF cooler outlet line (E) with the new sealing washers (F).
36. Install the breather cap (A) securely on the breather pipe (B) so its arrow (C) points to the front of the transmission (A/T clutch pressure control solenoid valves B and C side).
37. 4WD model: Install the transfer assembly (A) with the new O-ring (B) and dowel pin (C).
38. Install the ATF dipstick.

Scheme 283

Scheme 284

Carrier Bearing Replacement

Special Tools Required

Attachment, 40 x 50 mm 07LAD-PW50601

Note. The bearing and bearing outer race should be replaced as a set. Inspect and adjust the carrier bearing preload whenever bearing is replaced. Check the bearing for wear and rough rotation. If the bearing is OK, removal is not necessary. The illustration shows 4WD model; 2WD model is similar.

Scheme 285

Scheme 286

1. Remove the carrier bearing (A) with a commercially available puller (B), bearing separator (C), and stepper adapter (D).
2. Install the new bearings with the special tool and a press. Press the bearing on securely so there is no clearance between the bearing and the differential carrier.

Scheme 287

1. Remove the final driven gear (A) and transfer drive gear (B) from the differential carrier (C). NOTE: The final driven gear bolts have left-hand threads.
2. Install the final driven gear with the chamfered side on the inner bore facing the differential carrier.
3. Tighten the bolts to the specified torque in a crisscross pattern.

Scheme 288

1. Remove the final driven gear (A) from the differential carrier (B). NOTE: Differential carrier bolts have left-hand threads.
2. Install the final driven gear in the direction shown on the differential carrier.
3. Tighten the bolts to the specified torque in a crisscross pattern.

Oil Seal Replacement

Special Tools Required

1. Driver 07749-0010000
2. Oil seal driver attachment 07947-SD90101
3. Oil seal driver attachment 07JAD-PH80101

Note. The illustration shows 4WD model; 2WD model is similar.

Scheme 289

Scheme 290

Scheme 291

Scheme 292

1. Remove the oil seal from the transmission housing.
2. Remove the oil seal from the torque converter housing.
3. Install the new oil seal (A) in the transmission housing with the special tools.
4. Install the new oil seal (A) in the torque converter housing with the special tools.

Carrier Bearing Outer Race Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 78 x 90 mm 07GAD-SD40101
3. Attachment, 72 x 75 mm 07746-0010600

Note. The bearing and bearing outer race should be replaced as a set. Replace the bearing with a new one whenever the outer race is replaced. Do not use the thrust shim on the torque converter housing. Adjust bearing preload after replacing the bearing and outer race. Coat all parts with ATF during installation. The illustration shows 4WD model; 2WD model is similar.

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

1. Remove the bearing outer race (A), 76.2 mm thrust washer (B), and 76 mm thrust shim (C) from the transmission housing (D) by heating the housing to about 212°F (100°C) with heat gun (E). Do not heat the housing in excess of 212°F (100°C). NOTE: Let the transmission housing cool to room temperature before installing the bearing outer race.
2. Remove the bearing outer race (A) and 80 mm thrust washer (B) from the torque converter housing (C).
3. Install the 80 mm thrust washer and the new bearing outer race in the torque converter housing.
4. Drive the bearing outer race securely in the housing with the special tools.
5. Install the 76 mm thrust shim (A), 76.2 mm thrust washer (B), and the new bearing outer race (C) in the transmission housing (D).
6. With the special tools, drive the bearing outer race in securely so there is no clearance between the outer race, thrust washer, shim, and housing.

Transfer Holder Roller Bearing Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 62 x 68 mm 07746-0010500

Scheme 298

Scheme 299

1. Remove the roller bearing from the transfer holder.
2. Install the new roller bearing in the transfer holder with the special tools.

Transfer Holder Tapered Roller Bearing Outer Race Removal/Installation

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 62 x 68 mm 07746-0010500

Scheme 300

Scheme 301

1. Remove the tapered roller bearing outer race (A) and 68 mm thrust shim (B) from the transfer holder.
2. Install the 68 mm thrust shim (A) in the transfer holder, then install the tapered roller bearing outer race (B) with the special tools.

Transfer Drive Gear Bearing Replacement

Special Tools Required

1. Driver 07749-0010000
2. Attachment, 37 x 40 mm 07746-0010200
3. Attachment, 42 x 47 mm 07746-0010300

Scheme 302

Scheme 303

1. Remove the tapered roller bearing (A) from the transfer drive gear (B) with the special tools, bearing separator (C) and a press.
2. Install the new tapered roller bearing (A) on the transfer drive gear (B) with the special tools and a press.

Transfer Output Shaft Bearing Removal/Installation

Special Tools Required

1. Driver, 40 mm I.D. 07746-0030100
2. Attachment, 35 mm I.D. 07746-0030400

Scheme 304

Scheme 305

1. Remove the tapered roller bearing (A) from the transfer output shaft (B) with a bearing separator (C) and a press. Place a shaft protector (D) between the transfer output shaft and the press to prevent damaging the transfer output shaft.
2. Install the 35 mm thrust shim (A) on the transfer output shaft (B).
3. Install the tapered roller bearing (C) on the transfer output shaft with the special tools and a press.

Transfer Housing Tapered Roller Bearing Outer Race Replacement

Special Tools Required

1. Driver 07749-0010000
2. Oil seal driver attachment 07947-SD90101
3. Bearing installer attachment 07KAF-PS30120
4. Bearing installer attachment 07LAF-PZ70110
5. Installer shaft 14 x 165 mm 07JAF-SJ80110
6. Installer nut 14 mm 07JAF-SJ80120

Note. Replace the bearing with a new one whenever the outer race is replaced.

Scheme 306

Scheme 307

Scheme 308

Scheme 309

1. Remove the bearing outer races from the transfer housing by heating the housing to about 212°F (100°C) with a heat gun. Do not heat the housing more than 212°F (100°C). NOTE: Some 57 mm bearing outer races are not press-fitted, and can be removed without heating the housing. Bearing Outer Race Locations
2. Install the 57 mm bearing outer race (A) in the housing (B) with the special tools.
3. Install the 62 mm bearing outer race and 50 mm bearing outer race in the housing with the special tools.