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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.
(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 sur-
face is flush with the manual valve lever sur-
face. (c) Assemble a new collar to the manual valve lever.
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5. INSTALL FIRST AND REVERSE BRAKE PISTON TO
TRANSMISSION CASE
(a) Coat the new 4±rings with ATF.
(b) Install the two O±rings on the piston. 4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the
manual valve fever is in the P range. 3. INSTALL PARKING LOCK PAWL BRACKET
Torque: 75 kg±cm (65 in.±Ib, 7.4 N±m)
(g) Match the collar hole to the lever calking hollow
and calk the collar to the lever.
(h) Install the retaining spring.
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(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. 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)
8. INSTALL OVERDRIVE UNIT
(a) Install the overdrive brake apply gasket and overdrive
clutch apply gasket. (c) Push the piston into the bore of the case, facing
the spring seat upward.
7. INSTALL SNAP RING TO TRANSAXLE CASE
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9. CHECK INTERMEDIATE SHAFT END PLAY
(a) Make sure that the intermediate shaft has thrust plate)
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 installa-
tion of intermediate shaft.
(See page AT±306)
(b) Make sure that the intermediate shaft turns smoothly.(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.
Torque: 250 kg±cm (18 ft±Ib, 25 N±m)
HINT: Each bolt length (mm (in.)) is indicated in the figure. (e) Place the new gasket onto the transaxle case.
M Install the overdrive assembly with overdrive
case to the transaxle 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.) (b) Install the overdrive brake drum to the case.
(c) Install the new case gasket to the case.
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10. INSTALL REAR PLANETARY GEAR
(a) Install the rear planetary ring gear.
(b) (A540E)
Place the bearing onto the ring gear.
(e) (A540H)
Coat the races and bearing with petroleum jelly and
install them onto the ring gear.
Bearing and race: mm (in.)
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.
HINT: Be sure that the end gap of the snap ring is
not aligned with one of cutouts.(d) Coat the thrust washer with petroleum jelly and
place it onto the rear planetary gear.
(3) Install the rear planetary gear.
Front Race
mm (in.)
Rear Race A540HBearing
Bearing A540E
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(c) Install the snap ring.
HINT: 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. (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.) 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) 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. 13. INSTALL NO. 2 ONE±WAY CLUTCH INTO CASE
(a) Place the No. 2 one±way clutch with the shiny side of
flange upward.
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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 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. 14. INSTALL SECOND COAST BRAKE BAND GUIDE
(c) Place the piston return spring into the case.
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(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.
19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
(a) Coat the thrust washer with petroleum jelly an install
it on the sun gear input drum. 18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket
and confirm that the piston moves. 17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the sec-
ond brake drum.(d) Place the second brake drum into the case.
HINT: Align the groove of the drum with the bolt.
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