Page 489 of 2389
REMOVAL AND INSTALLATION OF TRANSAXLE
(A540E and A540H)
REMOVAL AND INSTALLATION OF ENGINE
(3S±FE: See pages EM±106 and EM±t30, 2VZ±FE: EM±138 and EM±165)
REMOVAL AND INSTALLATION OF TRANSAXLE
(Remove and install transaxle as shown)
± AUTOMATIC TRANSAXLERemoval and Installation of Transaxle (A540E and
A540H)AT±234
Page 490 of 2389
3. INSTALL TORQUE CONVERTER MOUNTING BOLTS
(a) Clean the threads of the bolts with the gasoline.
(b) Coat the threads of the bolts with sealer.
Sealer: Part No. 08833±00070, THREE BOND 1324
or equivalent.
(c) Tighten the bolts evenly.
Torque: 280 kg±cm (20 ft±Ib, 27 N±m)
2. CHECK TORQUE CONVERTER INSTALLATION
Using a scale and a straight edge, measure from the
installed surface to the front surface of the transaxle
housing.
Correct distance: 23.0 mm I0.906 in.) or more
4. (A540H, Transfer)
INSPECT MODE SELECT LEVER POSITION
After finishing inspection or repair the transaxle, be sure
the mode select lever position to FREE mode and at-
tach the lock bolt.
(MAIN POINT OF INSTALLATION)
1. INSTALL TORQUE CONVERTER IN TRANSAXLE
± AUTOMATIC TRANSAXLERemoval and Installation of Transaxle (A540E and
A540H)AT±235
Page 491 of 2389

COMPONENT PARTS
General Notes
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar±looking parts of different subassemblies being on your
workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next
component group. If a component group can not be assembled because parts are being ordered,
be sure to
keep all parts of that group in a separate container while proceeding with disassembly, inspection,
repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: A540E ATF DEXRONII
A540H ATF Type T or equivalent
Recommended oil for the transfer: Transaxle oil E50, API GL5, SAE 75W±90 or equivalent
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean, with any fluid passages and holes blown through with
compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying
automatic transaxle fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection, repairs, and reas-
sembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least
fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O±rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the
groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
± AUTOMATIC TRANSAXLEComponent Parts (General Notes) (A540E and A540H)AT±262
Page 492 of 2389
DISASSEMBLY OF SECOND COAST BRAKE
PISTON
1. REMOVE OIL SEAL RING
Remove the oil seal ring from the piston.
2. REMOVE PISTON ROD
(a) Remove the E±ring while pushing the piston with
needle±nose pliers.
COMPONENT PARTS
Second Coast Brake
± AUTOMATIC TRANSAXLEComponent Parts (Second Coast Brake) (A540E and
A540H)AT±263
Page 493 of 2389
ASSEMBLY OF SECOND COAST BRAKE
PISTON
1. SELECT PISTON ROD
If the band is OK but piston stroke not within the standard value,
select the piston rod.
Piston stroke: 2.0 ± 3.5 mm (0.079 ± 0.138 in.)
There are two lengths of piston rod.
Piston rod length: 95.2 mm l3.748 in.)
96.3 mm (3.791 in.)
2. INSTALL PISTON ROD
(a) Install the plate washer and inner spring to the piston
rod. INSPECTION OF SECOND COAST BRAKE
COMPONENT
If the lining of the brake band is exfoliated or discol-
ored,
or even part of the printed marks is defaced, replace the
brake band.(b) Remove the inner spring, plate washer and pis-
ton rod.
(b) Install the E±ring while pushing the piston.
± AUTOMATIC TRANSAXLEComponent Parts (Second Coast Brake) (A540E and
A540H)AT±264
Page 494 of 2389
3. INSTALL OIL SEAL RING
(a) Apply ATF to the oil seal ring.
(b) Install the oil seal ring to the piston.
NOTICE: Do not spread the ring ends more than
necessary.
± AUTOMATIC TRANSAXLE(Second Coast Brake) (A540E and A540H)AT±265
Page 495 of 2389
DISASSEMBLY OF OIL PUMP
1. REMOVE OIL SEAL RINGS
Remove the two oil seal rings from the stator shaft
back side.
2. REMOVE THRUST WASHER FROM STATOR SHAFT
BACK SIDE
Oil Pump
± AUTOMATIC TRANSAXLEComponent Parts (Oil Pump) (A540E and A54CH)AT±266
Page 496 of 2389

INSPECTION OF OIL PUMP
1. CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body.
Using a feeler gauge, measure the clearance.
Standard body clearance: 0.07 ± 0.15 mm
(0.0028 ± 0.0059 in.)
Maximum body clearance: 0.3 mm (0.012 in.)
If the body clearance is greater than the maximum,
replace the oil pump body subassembly.
2. CHECK TIP CLEARANCE OF DRIVEN GEAR
Measure between the driven gear teeth and the cres-
cent shaped part of the pump body.
Standard tip clearance: 0.11 ± 0.14 mm
(0.0043 ± 0.0055 in.)
Maximum tip clearance: 0.3 mm (0.012 in.)
If the tip clearance is greater than the maximum, re-
place the oil pump body subassembly.
3. CHECK SIDE CLEARANCE OF BOTH GEARS
Using a steel straightedge and a feeler gauge, mea-
sure the side clearance of both gears.
Standard side clearance: 0.002 ± 0.005 mm
(0.0008 ± 0.0020 in.)
Maximum side clearance: 0.1 mm (0.004 in.) 3. REMOVE STATOR SHAFT
Remove the eleven bolts and stator shaft.
HINT: Keep the gears in assembly order.
4. REMOVE FRONT OIL SEAL
Pry off the oil seal with a screwdriver.
± AUTOMATIC TRANSAXLEComponent Parts (Oil Pump) (A540E and A540H)AT±267