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42. (A140E)
INSTALL SOLENOID WIRING
(A 140 L)
INSTALL KICK±DOWN SWITCH WIRING
Push the solenoid wiring through the case, being careful
not to damage the O±ring. Check for full seating.
44. INSTALL BOLTS IN VALVE BODY
HINT: Each bolt length (mm (in.)) is indicated in the figure.
Hand tighten the twelve bolts A140E) of fourteen bolts
(A140L) first, then torque with a torque wrench.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
43. PLACE VALVE BODY ON TRANSMISSION
(a) While holding the cam down with your hand, slip
the cable end into the slot.
(b) Lower the valve body into place.
NOTICE: Do not entangle the kick±down switch wire or so-
lenoid wire.
5. (A140E)
CONNECT SOLENOID WIRING
(a) Connect the No. 1 solenoid connector. (white and
shorter wire)
(b) Connect the No. 2 solenoid connector. (black and
longer wire)
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47. INSTALL MANUAL VALVE BODY AND DETENT
SPRING
HINT: 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 four bolts first. Then, tighten them with
a torque wrench.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
(d) Place the detent spring on the manual valve body and
hand tighten the two bolts first.
Then, tighten them with a torque wrench.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
48. INSTALL OIL TUBES
Using a plastic hammer, install the tubes into the posi-
tions indicated in the figure.
NOTICE: Be careful not to bend or damage the tubes.
46. (A140L)
CONNECT KICK±DOWN SWITCH WIRING
Connect the kick±down switch connector and clamp it
onto the bracket.
49. INSTALL TUBE BRACKET
Each bolt length (mm (in) is indicated in the figure.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
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Page 435 of 2389
54. (140L)
INSTALL GOVERNOR BODY
(a) Install the governor body adaptor.
(b) Install the governor body with the plate washer.
(c) Install the thrust washer onto the governor body.
(d) Install the new O±ring to the cover.
(e) Install the cover to the case. 53. (A140E)
INSTALL NO. 2 SPEED SENSOR
(a) Install the speed sensor with a new O±ring.
(b) Install the cover bracket with the two bolts. 50. INSTALL OIL STRAINER
Each bolt length (mm (in.)) is indicated in the figure.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
51. INSTALL MAGNETS IN PLACE AS SHOWN
NOTICE: Make sure that the magnets do not interfere with
the oil tubes.
52. INSTALL OIL PAN WITH NEW GASKET
Torque: 50 kg±cm (43 in.±Ib, 4.9 N±m)
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60. INSTALL NEUTRAL START SWITCH
(a) Install the neutral start switch to the manual valve shaft.
(b) Install the seal gasket and locking plate.
(c) Tighten the nut and stake it with the locking plate.
Torque: 70 kg±cm (61 in.±Ib. 6.9 N±m)
56. (A140E)
INSTALL SOLENOID WIRING RETAINING PLATE
57. INSTALL THROTTLE CABLE RETAINING PLATE
58. INSTALL FILLER TUBE AND DIPSTICK
59. INSTALL SOLENOID
(a) Coat the O±rings with ATF and push the tip of solenoid
into the hole.
(b) Tighten the two bolts evenly and gradually.
61. ADJUST NEUTRAL START SWITCH
(a) Align the groove and return neutral basic line. 55. INSTALL COVER BRACKET
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63. INSTALL UNION AND ELBOW
(a) Coat a new O±rings with ATF.
(b) Install the O±rings to the union and elbow.
(e) Install the union and elbow to the transaxle case.
Torque: 275 kg±cm (20 ft±Ib, 27 N±m)
(b) Lock the switch with two bolts.
Torque: 55 kg±cm (48 in.±Ib, 5.4 N±m)
62. INSTALL MANUAL SHIFT LEVER
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A540E AND A540H
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLEAT±183
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DESCRIPTION
GENERAL
(A540E)
The A540E is a 4±speed, Electronic Controlled Transaxle (hereafter called ECT) developed exclusively for
use with a transversely±mounted engine. A lock±up is built into the torque converter.
The A540E transaxle is mainly composed of the torque converter, the 4±speed planetary gear unit, the
differential, the hydraulic control system and the electronic control system.
± AUTOMATIC TRANSAXLEDescription (A540E and A540H)AT±184
Page 440 of 2389
(A540H)
The A540H automatic transaxle design is based on the A540E automatic transaxle and equipped with
a center differential and transfer.
This transaxle has the same hydraulic multiplate clutch in the center differential limiting control mecha-
nism as the A241 H automatic transaxle on the Corolla All±TRAC/4WD Station Wagon. The fluid pres-
sure acting on the hydraulic multiplate clutch of the A540H is controlled by the ECT ECU (Electronic
Control Unit according to the vehicle driving conditions. As a result, torque is distributed to the front
and rear wheels appropriately at all times to maximize the overall performance of the 4WD vehicle.
NOTICE: Special handling methods are necessary for full±time 4WD vehicles during inspection and mainte-
nance. Instructions concerning these handling methods are given on page IN±8.
± AUTOMATIC TRANSAXLEDescription (A540E and A540H)AT±185