Part 3
24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
a. Coat the race and bearing with petroleum jelly and install it onto rear side of the forward clutch.
b. Coat the race and bearing with petroleum jelly and install it onto front side of the forward clutch.
NOTE: There are two different-thick races (A540H) and bearings (A540E) for adjustment of the input shaft thrust play.
c. Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.
d. Mesh the hub of the forward clutch with flukes of the direct clutch discs.
NOTE: Be careful that the bearing and thrust washer do not get out of place.
e. Install the direct clutch and forward clutch into the case.
NOTE: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place.
f. Check the distance between the direct clutch drum and the sun gear input drum.
Distance: Approx. 3 mm (0.12 in.)
25. INSTALL OIL PUMP INTO CASE
a. Coat a new O-ring with ATF and install it to the oil pump.
b. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.
c. Install and tighten the seven bolts.
Torque: 225 kg.cm. (16 ft.lb., 22 N.m)
26. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.
Thrust play: 0.13 - 0.90 mm (0.0051 - 0.0354 in.)
NOTE: There are two different-thick bearings (A540E) or races (A540H) for the end of stator shaft. If the thrust play is in excess of standard, select one of them.
(A540E) Bearing thickness:
3.60 mm (0.1417 in.)
4.19 mm (0.1650 in.)
(A540H) Race thickness:
0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
27. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
28. INSTALL SECOND COAST BRAKE PISTON
a. Coat the new O-rings with ATF and install it to the cover.
b. Install the outer spring with the piston.
c. Place the cover into the bore.
d. Using SST, install the snap ring while pressing the cover.
SST 09350-32014 (09351-32050)
e. Check that the front end of the piston rod contacts the center of the second brake band depression.
29. CHECK SECOND COAST BRAKE PISTON STROKE
a. Apply a small amount of paint to the piston rod at the point it meets the case shown in the illustration.
b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/Sq. cm, 57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 in.)
If the stroke is more than specified, replace the piston rod with a longer one.
Piston rod length: 95.2 mm (3.748 in.) 96.3 mm (3.791 in.)
It is still more than standard value, replace the brake band with a new one.
30. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Install the new O-rings to the pistons.
b. Install the springs and pistons into the bores.
c. Place the cover with a new gasket and gradually tighten the bolts a little a time in sequence.
NOTE: Each bolt length (mm (in.)) is indicated in the figure.
Torque: 100 kg.cm. (7 ft.lb., 10 N.m)
31. PLACE NEW SECOND BRAKE APPLY GASKET
32. INSTALL THROTTLE CABLE AND SOLENOID WIRE
33. INSTALL VALVE BODY TO TRANSAXLE CASE
a. While holding the cam down with your hand, slip the cable end into the slot.
b. Lower the valve body into place.
CAUTION: Do not entangle the solenoid wire.
c. Install and tighten the ten bolts.
NOTE:
- Each bolt length (mm (in.)) is indicated in the figure.
- Hand tighten the ten bolts first, then torque with a torque wrench.
Torque: 110 kg.cm. (8 ft.lb., 11 N.m)
34. INSTALL B3 APPLY TUBE
CAUTION: Be careful not to bend or damage the tube.
35. INSTALL CONNECTOR CLAMP AND TUBE RETAINER
NOTE: Each bolt length (mm (in.)) is indicated in the figure.
Torque: 110kg.cm. (8 ft.lb., 11 N.m)
36. CONNECT SOLENOID CONNECTORS
37. INSTALL OIL TUBES
(A540E)
- Using a plastic hammer, install the tubes into the positions indicated in the figure.
(A540H)
- Using a plastic hammer, install the tubes into the positions indicated in the figure.
- Install the bolt.
Torque: 55 kg.cm. (48 in-lb, 5.4 N.m)
NOTE: Each bolt length (mm (in.)) is indicated in the figure.
CAUTION: Be careful not no bend or damage the tubes.
38. INSTALL MANUAL VALVE BODY AND DETENT SPRING
NOTE: Each bolt length (mm (in.)) is indicated in the figure.
a. Align the manual valve with the pin on the manual shaft lever.
b. Lower the manual valve body into place.
c. Hand tighten the five bolts first. Then, tighten them with a torque wrench.
Torque: 110kg.cm. (8 ft.lb., 11 N.m)
d. Place the detent springs on the manual valve body and hand tighten the two bolts first.
Then, tighten them with a torque wrench.
Torque: 110kg.cm. (8 ft.lb., 11 N.m)
NOTE: Each bolt length (mm (in.)) is indicated in the figure.
e. Check that the manual valve lever is touching the center of the detent spring tip roller.
39. INSTALL TUBE BRACKET AND OIL STRAINER
Each bolt length (mm (in.)) is indicated in the figure.
Torque:
Tube bracket: 100 kg.cm. (7 ft.lb., 10 N.m)
Oil strainer: 110kg.cm. (8 ft.lb., 11 N.m)
40. INSTALL MAGNETS IN PLACE AS SHOWN
CAUTION: Make sure that the magnets do not interfere with the oil tubes.
41. INSTALL OIL PAN WITH NEW GASKET
Torque: 50 kg.cm. (43 in-lb, 4.9 N.m)
42. (A540E) INSTALL SPEED SENSOR
a. Install a new O-ring to the speed sensor.
b. Install the speed sensor to the transaxle case.
c. Tighten the bolt.
d. Connect the sensor connector.
43. (A540H) INSTALL VEHICLE SPEED SENSOR
a. Install a new O-ring to the vehicle speed sensor
b. Install the vehicle speed sensor to the transaxle case.
c. Install and tighten the bolt.
44. INSTALL THROTTLE CABLE RETAINING PLATE
45. INSTALL SOLENOID WIRE
46. INSTALL NEUTRAL START SWITCH
a. Install the neutral start switch to the manual valve shaft.
b. Place the new locking piate and tighten the nut.
c. Stake the nut with locking plate.
d. Install the two bolts.
e. Adjust the neutral start switch.
NOTE: Align the groove and neutral basic line.
f. Tighten the two bolts.
47. INSTALL MANUAL SHIFT LEVER
48. INSTALL UNION AND ELBOW
a. Install the new O-rings to the union and elbow.
b. Install the union and elbow to the transaxle case.
Torque: 275 kg.cm. (20 ft.lb., 27 N.m)
NOTE: Install the elbow at right angles to the bottom of the transaxle case.
49. (A540H) INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Install a new snap ring to the shaft groove.
b. Using a plastic hammer, install the shaft.
NOTE: Keeping the intermediate shaft on the pinion shaft of differential, measure the point in the illustration.
Protrusion length (Reference): 255.5 mm (10.059 in.)
50. (A540H) INSTALL APPLY GASKET
Install a new apply gasket to the differential carrier cover
51. (A540H) INSTALL TRANSFER ASSEMBLY
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transfer and transaxle.
b. Apply seal packing to the transaxle as shown in the illustration.
Seal packing: Part No.08883-00090, Adhesive 1131, THREE BOND 1131, Loctite 518, or equivalent
NOTE: Install the transfer assembly as soon as the seal packing is applied.
c. Coat the threads of bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent.
d. Install and torque the five nuts and three bolts.
Torque: 700 kg.cm. (ft.lb., 69 N.m)
52. (A540H) INSPECT MODE SELECT LEVER POSITION
After finishing inspection or repair the transaxle, be sure the select lever position to FREE mode and attach the lock bolt.