Transmission Reassembly

Special Tools Required 

Mainshaft Holder Set 07PAB-0010001

1. Make sure that the ATF magnet (A) is cleaned and installed in the torque converter housing. Clean and install the ATF magnet, if necessary.
   Fig 1: Transmission Assembly Related Replacement Components With Torque Specifications

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Install the main separator plate (B) and the two dowel pins (C) on the torque converter housing.
3. Install the ATF pump drive gear (D), the ATF pump driven gear (E), and the ATF pump driven gear shaft (F). Install the ATF pump driven gear with its grooved and chamfered side facing down.
4. Install the main valve body (G) (eight bolts).
5. Install the 4th/reverse air check valve (H).
6. Make sure the ATF pump drive gear (A) rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft (B) moves smoothly in the axial and normal operating direction.
   Fig 2: Rotating ATF Pump Drive Gear

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7. If the ATF pump drive gear and ATF pump driven gear shaft do not move smoothly, loosen the main valve body bolts. Realign the ATF pump driven gear shaft, and retighten the bolts to the specified torques, then recheck. 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.
8. Install the two check balls (A) in the main valve body.
   Fig 3: Check Balls, Regulator Separator Plate, Dowel Pins, Regulator Valve Body, Manual Separator Plate And Manual Valve Body With Torque Specifications

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9. Install the regulator separator plate (B) and the two dowel pins (C) on the main valve body, and install the regulator valve body (D) (eight bolts).
10. Install the manual separator plate (E) and the two dowel pins (F) on the main valve body, and install the manual valve body (G) (seven bolts).
11. Install the two dowel pins (A) on the main valve body.
    Fig 4: Dowel Pins, Stator Shaft, O-Rings, Stator Shaft Support, Air Check Valves And Stator Shaft Stop With Torque Specifications

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12. Install the stator shaft (B) with new O-rings (three) (C), and install the stator shaft support (D) (four bolts).
13. Install the 3rd air check valve (E) and the 6th air check valve (F).
14. Install the stator shaft stop (G) in the torque converter housing.
15. Install the cooler retainer cap (A).
    Fig 5: Cooler Retainer Cap With Mounting Bolts With Torque Specifications

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16. Install the 2nd air check valve (A), the 5th air check valve (B), and the oil catch plate (C).
    Fig 6: 2nd Air Check Valve, 5th Air Check Valve, Oil Catch Plate, Transfer Output Shaft, Thrust Shim And Differential Assembly With Torque Specifications

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17. Install the transfer output shaft (D) in the torque converter housing, and install the thrust shim (E) on the top of the transfer output shaft.
18. Install the differential assembly (F) in the torque converter housing.
19. Install the selector control shaft (G).
20. Align the control lever pin (A) with the manual valve guide (B).
    Fig 7: Aligning Control Lever Pin With Manual Valve Guide

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21. Hook the detent spring (A) to the detent arm (B) and the selector control shaft (C), then install the detent arm and the detent arm shaft (D) into the torque converter housing.
    Fig 8: Identifying Detent Spring, Detent Arm, Selector Control Shaft And Detent Arm Shaft

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22. Install the parking holder (A).
    Fig 9: Parking Holder And Third Shaft With Mounting Bolts With Torque Specifications

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23. Install the third shaft (B) into the main valve body.
24. Assemble the mainshaft, the countershaft, the secondary shaft, and the idler gear shaft.
25. Install the thrust needle bearing (A) on the secondary shaft bearing in the torque converter housing.
    Fig 10: Identifying Thrust Needle Bearing, Mainshaft Subassembly, Countershaft Subassembly, Thrust Needle Bearing And Washer

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26. Join the mainshaft subassembly (B), the countershaft subassembly (C), the secondary shaft subassembly (D), and the idler gear shaft subassembly (E) together, and install them in the torque converter housing. Install the 27.5 x 41 x 2.5 mm thrust needle bearing (F) and the 41.5 mm washer (G) on the top of the idler gear shaft.
27. Turn the shift fork shaft (A) so the large chamfered hole is facing the fork bolt hole of the shift fork.
    Fig 11: Shift Fork Shaft, Baffle Plate, Shift Fork, Reverse Selector Hub And Reverse Gear With Torque Specifications

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28. Install the baffle plate (B), the shift fork (C), the reverse selector hub (D), and the reverse gear (E) together.
29. Secure the shift fork (A) to the shift fork shaft with the lock bolt and a new lock washer (B), then bend the lock tab of the lock washer against the bolt head.
    Fig 12: Shift Fork, Lock Washer With Mounting Bolt With Torque Specifications

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30. Install the lubrication pipe (A) and the 10x70 mm ATF joint pipe (B) into the regulator valve body (C).
    Fig 13: Lubrication Pipe, ATF Joint Pipe, Regulator Valve Body, ATF Strainer And O-Ring With Torque Specifications

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31. Install the ATF strainer (D) with a new O-ring (E).
32. Install new O-rings (C) (four) on ATF joint pipes A and B, and install the joint pipes into the manual valve body (D) and the torque converter housing (E).
    Fig 14: Identifying O-Rings, ATF Joint Pipes, Manual Valve Body And Torque Converter Housing

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33. Install the two dowel pins (A) and a new gasket (B) on the torque converter housing (C).
    Fig 15: Identifying Dowel Pins, Gasket, Torque Converter Housing And Transmission Housing

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34. Place the transmission housing (D) on the torque converter housing.
35. Wrap a screwdriver tip with tape to prevent damaging the reverse idler gear teeth. Engage the reverse idler gear with the reverse gears by rotating the idler gear using a screwdriver.
    Fig 16: Engaging Reverse Idler Gear With Reverse Gears

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36. While expanding the snap ring of the countershaft bearing using snap ring pliers, install the transmission housing onto the bearing part-way. Then release snap ring pliers, and push down on the transmission housing until it bottoms and snap ring snaps into place on the countershaft bearing snap ring groove.
    Fig 17: Installing Snap Ring

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37. Install the transmission housing mounting bolts along with transmission hanger C, and tighten the bolts in at least two steps in a criss-cross pattern to the specified torques.
    Fig 18: Transmission Hanger And Transmission Housing Mounting Bolts With Torque Specifications

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38. Install the mainshaft holder onto the mainshaft.
    Fig 19: Installing Mainshaft Holder Onto Mainshaft

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39. Install the control lever (A) over the selector control shaft (B). Secure the control lever with a new lock washer (C) and the bolt, then bend the lock tab of the lock washer against the bolt head.
    Fig 20: Control Lever, Selector Control Shaft, Control Lever And Lock Washer With Mounting Bolt With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
40. Shift the transmission in the P position by rotating the control lever. Do not use the control shaft to adjust the shift position. If the selector control shaft tips are squeezed together, it will cause a faulty signal or position due to play between the control shaft and the transmission range switch.
    Fig 21: Rotating Control Lever

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41. Install the old lock washers (A) with the marked side (B) up over the mainshaft (C) and the third shaft (D), and apply ATF to surfaces of the old lock washers and the old locknuts (E).
    Fig 22: Installing Splined Washers With Marked Side Up Over Mainshaft And Third Shaft With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
42. Install the old locknuts, and tighten them to seat the lock washers to the specified torques, then remove the old locknuts and the old lock washers.
    NOTE: The third shaft locknut has left-hand threads.
43. Install new locknuts and new lock washers, and tighten them to the specified torques, then stake the locknuts into the shafts to a depth (A) of 0.7-1.3 mm (0.028-0.051 in) using a 3.5 mm punch (B).
    NOTE:

    • Do not rotate the locknuts in the reverse direction after the locknuts are seated to the lock washers.
    • The third shaft locknut has left-hand threads.
      Fig 23: Installing Locknuts And Splined Washers With Torque Specifications

      Courtesy of AMERICAN HONDA MOTOR CO., INC.
44. Install transmission hanger A.
    Fig 24: Transmission Hanger, O-Ring, Mainshaft End Cover, Third Shaft End Cover And ATF Filter Bracket With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
45. Install a new O-ring (B) on the mainshaft end cover (C), and install the mainshaft end cover. Install a new O-ring (D) on the third shaft end cover (E), and install the third shaft end cover with the ATF filter bracket (F).
46. Install new O-rings (G) on the end covers (H), and install the end covers.
47. Apply ATF to new O-rings (A), and install the O-rings over the ATF pipes (B). Then install the ATF pipes with the filter ends (C) facing the secondary valve body (D) into the transmission.
    NOTE: There are 11 ATF pipes. Do not drop the ATF pipes into the transmission. If an ATF pipe is dropped into the transmission, the transmission will need to be disassembled.
    Fig 25: O-Rings, ATF Pipes, Filter Ends, Secondary Valve Body And Gasket With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
48. Install a new gasket (E) on the transmission housing.
49. Install the secondary valve body while aligning the ATF pipes with the pipe holes on the secondary valve body, and secure the secondary valve body with the bolts.
50. Install new O-rings (A) on shift solenoid valve C (B), and install shift solenoid valve C.
    Fig 26: O-Rings, Shift Solenoid Valve, Transmission Fluid Pressure Switch C (4th Clutch) And Sealing Washer With Torque Specifications

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51. Install transmission fluid pressure switch C (4th clutch) (C) with a new sealing washer (D). Tighten the switch by gripping the metal part, not the plastic part.
52. Install transmission fluid pressure switch A (2nd clutch) with a new sealing washer (C). Tighten the switch by gripping the metal part, not the plastic part.
    Fig 27: Transmission Fluid Pressure Switch A (2nd Clutch), Sealing Washer And Transmission Hanger With Torque Specifications

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53. Install transmission fluid pressure switch D (5th clutch) with a new sealing washer (E). Tighten the switch by gripping the metal part, not the plastic part.
54. Install transmission hanger B.
55. Install the ATF outlet line (A), and secure it with the banjo bolt (B) and new sealing washers (C), then secure the ATF outlet line with the bracket bolt.
    Fig 28: ATF Outlet Line, Banjo Bolt, Sealing Washers And ATF Inlet Line/ATF Hose/ATF Filter With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
56. Install the ATF inlet line/ATF hose/ATF filter (D), and secure it with the banjo bolt (E) and new sealing washers (F), then secure the ATF inlet line with the bracket bolt.
57. Put the ATF filter (G) on the ATF filter bracket (H), and secure it with the ATF filter holder (I) and the bolt.
58. Install a new O-ring (A) on the ATF temperature sensor (B), and install the ATF temperature sensor.
    Fig 29: O-Ring And ATF Temperature Sensor With Mounting Bolt With Torque Specifications

    Courtesy of AMERICAN HONDA MOTOR CO., INC.
59. Install a new O-ring (A) on the input shaft (mainshaft) speed sensor (B), and install the input shaft (mainshaft) speed sensor.
    Fig 30: O-Ring, Input Shaft (Mainshaft) Speed Sensor And Output Shaft (Countershaft) Speed Sensor With Torque Specifications

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60. Install a new O-ring (C) on the output shaft (countershaft) speed sensor (D), and install the output shaft (countershaft) speed sensor.
61. Shift the transmission into the N position by rotating the control lever from the P position. Do not use the control shaft to adjust the shift position. If the selector control shaft tips are squeezed together, it will cause a faulty signal or position due to play between the control shaft and the transmission range switch.
    Fig 31: Rotating Control Lever

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62. Align the cutouts (A) on the rotary-frame with the N positioning cutouts (B) on the transmission range switch (C), then put a 2.0 mm (0.079 in) feeler gauge blade (D) in the cutouts to hold the switch in the N position.
    NOTE: Be sure to use a 2.0 mm (0.079 in) blade or equivalent to hold the switch in the N position.
    Fig 32: Aligning Cutouts On Rotary-Frame With N Positioning Cutouts On Transmission Range Switch

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63. Install the transmission range switch (A) gently on the selector control shaft while holding it in the N position with the 2.0 mm (0.079 in) blade (B).
    Fig 33: Transmission Range Switch With Torque Specifications

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64. 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.
65. Install the ATF dipstick guide tubes (A) with new O-rings (B).
    Fig 34: ATF Dipstick Guide Tubes With O-Rings With Torque Specifications

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66. Install the ATF dipstick in the guide tube.