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There are three different thicknesses for drive and driven gears.
Drive and driven gear thickness
Mark Thickness
A 9.440 ± 9.456 mm (0.3717 ± 0.3723 in.)
B 9.456 ± 9.474 mm (0.3723 ± 0.3730 in.)
C 9.474 ± 9.490 mm (0.3730 ± 0.3736 in.)
If the thickest gear can not make the side clearance within
standard specification, replace the oil pump body subassembly.
4. CHECK OIL PUMP BODY BUSHING
Using a dial indicator, measure the inside diameter of the oil
pump body bushing.
Maximum inside diameter: 38.18 mm (1.5031 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body subassembly.
5. CHECK STATOR SHAFT BUSHING
Using a dial indicator, measure the inside diameter stator
shaft bushing.
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the inside diameter is greater than the maximum, replace
the stator shaft.
ASSEMBLY OF OIL PUMP
1. INSTALL FRONT OIL SEAL
Using SST and a hammer, install a new oil seal. The sea
end should be flush with the outer edge of the pump body
SST 09350±32014 (09351±32140)
Z. INSTALL DRIVEN GEAR AND DRIVE GEAR
Make sure the top of the gears are facing upward.
± AUTOMATIC TRANSAXLEComponent Parts toil Pump) (A540E and A540H)AT±268
Page 498 of 2389
5. INSTALL OIL SEAL RINGS
Install the two oil seal rings to the stator shaft back
side.
NOTICE: Do not spread the ring ends more than necessary.
HINT: After installing the oil seal rings, check that they
move smoothly. 3. INSTALL STATOR SHAFT TO PUMP BODY
(a) Align the stator shaft with each bolt hole.
(b) Torque the eleven bolts.
Torque: 100 kg±cm (7 ft±lb, 10 N±m)
4. INSTALL THRUST WASHER
(a) Coat the thrust washer with petroleum jelly.
(b) Align the tab of the washer with the hollow of the pump
body.
6. CHECK PUMP DRIVE GEAR ROTATION
Turn the drive gear with two screwdrivers and make
sure it rotates smoothly.
NOTICE: Be careful not to damage the oil seal lip.
± AUTOMATIC TRANSAXLEComponent Parts (Oil Pump) (A540E and A540H)AT±269
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DISASSEMBLY OF DIRECT CLUTCH
1. CHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST), mea-
sure the direct clutch piston stroke applying and
releasing the compressed air (4 ± 8 kg/cm2, 57 ±
114 psi, 392 ± 785 kPa) as shown.
SST 09350±32014 (09351±32190)
Piston stroke: A540E 0.91 ± 1.35 mm
(0.0358 ± 0.0531 in.)
A540H 1.11 ± 1.47 mm
(0.0437 ± 0.0579 in.)
If the piston stroke is greater than the maximum,
inspect each component.
Direct Clutch
± AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch) (A540E and A540H)AT±270
Page 500 of 2389
5.REMOVE CLUTCH PISTON
(a) Install the direct clutch onto the oil pump.
(b) Apply compressed air to the oil pump to remove the
piston. (If the piston does not come out completely,
use needle±nose pliers to remove it.)
(c) Remove the direct clutch from the oil pump. 4. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress the
springs with a shop press.
SST 09350±32014 (09351±32070)
(b) Remove the snap ring with snap ring pliers. 2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES
(d) Remove the two O±rings from the piston.(e) Remove the piston return spring.
± AUTOMATIC TRANSAXLE± Component Parts (Oil Pump) (A540E and A540H)AT±271
Page 501 of 2389

2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt If necessary, replace them.
HINT:
wIf the lining of the disc is exfoliated or discolored, or
even a part of the printed numbers are defaced, re-
place all discs.
w Before assembling new discs, soak them in ATF for
at least fifteen minutes.
ASSEMBLY OF DIRECT CLUTCH
1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
(a) Install new O±rings to the piston. Coat the O±ring:
with ATF.
(b) Being careful not to damage the O±rings, press the
piston into the drum with the cup side up.
INSPECTION OF DIRECT CLUTCH
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying low
pressure compressed air.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of
the direct clutch bushing.
Maximum inside diameter: 48.27 mm (1.9004 in.)
If the inside diameter is greater than the maximum, re-
place the direct clutch.
2. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring onto the piston
± AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch) (A540E and A540H)AT±272
Page 502 of 2389

5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST), measure
the direct clutch piston stroke applying and releasing
the compressed air (4 ± 8 kg/Cm2, 57 ±
114 psi, 392 ± 785 kPa) as shown.
SST 09350±32014 (09351±32190)
Piston stroke: A540E 0.91 ± 1.35 mm
(0.0358 ± 0.0531 in.)
A540H 1.11 ± 1.47 mm
(0.0437 ± 0.0579 in.)
If the piston stroke is nonstandard, select another
flange.
HINT: There are two different thicknesses for the flange.
Flange thickness: 2.70 mm (0.1063 in.)
3.00 mm (0.1181 in.) (b) Place SST on the spring retainer, and compress the
return spring with a shop press.
SST 09350±32014 (09351±32070)
(c) Install the snap ring using snap ring pliers. Be sure
the end gap of snap ring is not aligned with the spring
retainer claw.
3. INSTALL PLATES, DISCS AND FLANGE
(a) Install plates and discs.
Install in order: P=Plate D=Disc
P±D±P±D±P±D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned
with one of the cutouts.
± AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch) (A540E and A540H)AT±273
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REMOVAL OF COMPONENT PARTS (A540E and A540H)
COMPONENTS
± AUTOMATIC TRANSAXLERemoval of Component Parts (A540E and A540H)AT±236
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COMPONENTS (Cont'd)
± AUTOMATIC TRANSAXLERemoval of Component Parts (A540E and A540H)AT±237