Part 2

INSTALLATION OF 4-SPEED GEAR UNIT



1. INSTALL PARKING LOCK PAWL
a. Place the parking lock pawl onto the case.
Hook the spring ends to the case and pawl.
b. Install the pin into the hole of the case through the spring and pawl.

2. INSTALL MANUAL VALVE SHAFT



a. Coat the oil seal lip with the MP grease.
b. Install the manual valve shaft oil seal to the case.




c. Assemble a new collar to the manual valve lever.




d. Install the manual valve shaft to the transmission case through the manual valve lever.
e. Install the parking lock rod.




f. Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface.




g. Match the collar hole to the lever calking hollow and calk the collar to the lever.




h. Install the retaining spring.




3. INSTALL PARKING LOCK PAWL BRACKET

Torque: 75 kg.cm. (65 in.lb., 7.4 N.m)




4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P range.

5. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE



a. Coat the new O-rings with ATF.
b. Install the two O-rings on the piston.




c. Push the piston into the bore of the case, facing the spring seat upward.

6. INSTALL PISTON RETURN SPRING



a. Place the return spring and snap ring on the piston.
b. Place SST, and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)




c. Install snap ring. Visually check to make sure it is fully seated and centered by the three lugs on the spring retainer.
Be sure the end gap of snap ring is not aligned with the spring retainer claw.
d. Remove SST.




7. INSTALL SNAP RING TO TRANSAXLE CASE
8. INSTALL OVERDRIVE UNIT



a. Install the overdrive brake apply gasket and overdrive clutch apply gasket.




b. Install the overdrive brake drum to the case.
c. Install the new case gasket to the case.




d. Make sure that the length from the top surface of the case to the counter driven gear top surface should be about 24 mm (0.94 in.)




e. Place the new gasket onto the transaxle case.
f. Install the overdrive assembly with overdrive case to the transaxle case.




g. Coat the threads of 23 mm (0.91 in.) bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent.

h. Install and tighten the thirteen bolts.
NOTE: Each bolt length (mm (in.)) is indicated in the figure.

Torque: 250 kg.cm. (18 ft.lb., 25 N.m)




9. CHECK INTERMEDIATE SHAFT END PLAY
a. Make sure that the intermediate shaft has thrust play in axial direction.

Thrust play: 0.47 - 1.50 mm (0.0185 - 0.0591 in.)

If the thrust play is not within specification, check the installation of intermediate shaft.

b. Make sure that the intermediate shaft turns smoothly.

10. INSTALL REAR PLANETARY GEAR









a. Install the rear planetary ring gear.
b. (A540E) Place the bearing onto the ring gear.
c. (A540H) Coat the races and bearing with petroleum jelly and install them onto the ring gear.
d. Coat the thrust washer with petroleum jelly and place it onto the rear planetary gear.




e. Install the rear planetary gear.

11. INSTALL DISCS, PLATES AND FLANGE OF FIRST AND REVERSE BRAKE



a. Install the seven plates and seven discs.

Install in order: P = Plate D = Disc
A540E: P-D-P-D-P-D-P-D-P-D-P-D-P-D
A540H: P-D-P-D-P-D-P-D-P-D-P-D

b. Install the flange, facing the flat end downward.




c. Install the snap ring.

NOTE: Be sure that the end gap of the snap ring is not aligned with one of cutouts.

12. CHECK FIRST AND REVERSE BRAKE



a. Check the operation of the first and reverse brake piston.
Apply compressed air into the case passage and confirm that the piston moves.




b. Using a filler gauge, check the pack clearance of the first and reverse brake.

Clearance:
A540E: 0.85 - 2.05 mm (0.033 - 0.081 in.)
A540H: 1.04 - 2.16 mm (0.041 - 0.085 in.)

13. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE



a. Place the No.2 one-way clutch with the shiny side of flange upward.




b. Install the one-way clutch while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If can not turn the planetary gear clockwise, check the installation of the one-way clutch.




c. Install the snap ring.

NOTE: Be sure that the end gap of the snap ring is not aligned with one of cutouts.

d. (A540H only) Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear.




14. INSTALL SECOND COAST BRAKE BAND GUIDE
15. PLACE NO.1 ONE-WAY CLUTCH




a. Coat the thrust washer with petroleum jelly and install it on the No.1 one-way clutch. (A540E)




b. Place the No.1 one-way clutch onto the rear planetary gear.

16. INSTALL SECOND BRAKE




a. Install the flange, facing the flat end upward.
b. Install the three discs and plates.

Install in order: P Plate D = Disc
D-P-D-P-D-P




c. Place the piston return spring into the case.




d. Place the second brake drum into the case.

NOTE: Align the groove of the drum with the bolt.




e. Place the snap ring into the case so that end gap is installed into the groove.
f. While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove.
g. Be sure that the end gap of the snap ring is not aligned with one of cutouts.




17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the second brake drum.




18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket and confirm that the piston moves.

19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM




a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.




b. While turning the sun gear clockwise, install it into the No.1 one-way clutch.




20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT

NOTE: After installing the oil seal ring, check that it moves smoothly.













21. INSTALL FRONT PLANETARY GEAR
a. Coat the races and bearings with petroleum jelly, and install them onto the both sides of planetary gear.

NOTE: The bearings are the same on the (R) and (R) side (A540E).

b. Install the planetary gear onto the sun gear.

22. INSTALL FRONT PLANETARY RING GEAR




(A540H)
Coat the race with petroleum jelly and install it onto the tip of ring gear.

Race:
Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.)




23. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.