Automatic Transmission: Transmission: Reassembly

TORQUE: 12 N.m (1.2 kgf.m, 8.7 lbf.ft) 

Fig 1: Exploded View Of Transmission

Courtesy of AMERICAN HONDA MOTOR CO., INC.

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.
   Fig 2: Identifying ATF Pump Driven Gear And ATF Pump Driven Gear Shaft

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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.
   Fig 3: Identifying Detent Arm Shaft, Detent Arm, Manual Valve And Control Shaft

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8. Install the servo body and separator plate on the secondary valve body (seven bolts).
9. Install the servo detent base and the ATF strainer (two bolts).
10. Tighten the five bolts on the main valve body to 12 N.m (1.2 kgf.m, 8.7 lbf.ft).

    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.
    Fig 4: Checking ATF Pump Drive Gear

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 pipe in the main valve body, the three ATF feed pipes in the secondary valve and the four ATF feed pipes in the servo body.
    Fig 5: Exploded View Of Transmission With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
17. Install the reverse idler gear and the gear shaft holder (see REVERSE IDLER GEAR  ).
18. Install the differential assembly in the torque converter housing.
19. Assemble the mainshaft and the countershaft sub-assembly, then install them together in the torque converter housing.
    Fig 6: Identifying Mainshaft And Countershaft Sub-Assembly

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
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 torque the lock bolt. Bend the lock tab against the bolt head.
    Fig 7: Identifying Shift Fork And Lock Washer

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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.
    Fig 8: Aligning Spring Pin On Control Shaft With Transmission Housing Groove

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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.

    TORQUE: 44 N.m (4.5 kgf.m, 33 lbf.ft) 

    Fig 9: Identifying Transmission Housing Mounting Bolts Tightening Sequence

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26. Install the mainshaft speed sensor on the transmission housing.
27. Install the parking brake lever on the control shaft.
28. Assemble the one-way clutch and the parking gear with the countershaft 1st gear (see ONE-WAY CLUTCH  ).
29. Lubricate the following parts with ATF:
    • Countershaft threads
    • Old locknut threads and flat end
    • Old conical spring washer
    • Parking gear contact area with conical spring washer
30. Install the countershaft 1st gear collar, needle bearing, and the countershaft 1st gear/parking gear assembly on the countershaft.
31. Install the parking brake pawl shaft, pawl spring, pawl, and pawl stop on the transmission housing, then engage the parking brake pawl with the parking gear.
    Fig 10: Identifying Parking Brake Pawl Shaft, Pawl Spring, Pawl And Pawl Stop

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
32. Install the old locknut and conical spring washer on the countershaft. Tighten the old locknut to seat the parking gear to the specified torque, then remove them.
    NOTE:

    • The locknut has left-hand threads.
    • Do not use an impact wrench, always use a torque wrench to tighten the locknut.

    TORQUE: 103 N.m (10.5 kgf.m, 75.9 lbf.ft) 

    Fig 11: Identifying Locknut, Conical Spring Washer And Parking Gear

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33. Slip the special tool onto the mainshaft as shown.
    Fig 12: Identifying Mainshaft Holder

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34. Install the mainshaft 1st gear collar, mainshaft 1st gear, needle bearing, thrust needle bearing, and the thrust washer on the mainshaft.
35. Wrap the shaft splines with tape to prevent O-ring damage, then install new O-rings on the mainshaft.
36. Install the 1st clutch assembly on the mainshaft.
37. Install the new conical spring washer with the "C" facing the locknut side on the countershaft in the direction as shown.
38. Install the new conical spring washer with the "U" facing the locknut side on the mainshaft in the direction shown.
39. Lubricate the flat side of the new locknuts with ATF, then install and tighten the locknuts to the specified torque.

    TORQUE: 

    MAINSHAFT: 78 N.m (8.0 kgf.m, 58 lbf.ft) 

    COUNTERSHAFT: 103 N.m (10.5 kgf.m, 75.9 lbf.ft) 

    NOTE:

    • The locknuts have left-hand threads.
    • Do not use an impact wrench, always use a torque wrench to tighten the locknuts.
      Fig 13: Identifying Countershaft And Mainshaft Locknut

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
40. Stake each locknut using a 3.5 mm punch as shown.
    Fig 14: Staking Locknut With Torque Specifications

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41. Set the parking brake lever in the E position, then verify that the parking brake pawl engages the parking gear.
42. If the pawl does not engage fully, check the distance between the parking brake pawl shaft and the parking brake lever roller pin (see REVERSE IDLER GEAR  ).
43. Tighten the lock bolt and bend the lock tab.
    Fig 15: Checking Distance Between Parking Brake Pawl Shaft And Parking Brake Lever Roller Pin With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
44. Install the right side cover with two dowel pins and a new gasket (thirteen bolts).

    TORQUE: 12 N.m (1.2 kgf.m, 8.7 lbf.ft) 

    Fig 16: Identifying Right Side Cover

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45. Install the ATF cooler lines with new sealing washers.

    TORQUE: 28 N.m (2.9 kgf m, 21 lbf.ft) 

46. Install the ATF dipstick.