Page 657 of 2389
HINT: The bearings are the same on the (A) and (B)
side (A540E).
(b) Install the planetary gear onto the sun gear.
22. INSTALL FRONT PLANETARY RING GEAR
(A540H)
Coat the race with petroleum jelly and install it onto the
tip of ring gear.
Race: Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.) 21. INSTALL FRONT PLANETARY GEAR
(a) Coat the races and bearings with petroleum jelly, and
install them onto the both sides of planetary gear. 20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT
HINT: After installing the oil seal ring, check that it
moves smoothly.(b) While turning the sun gear clockwise, install it into
the No. 1 one±way clutch.
Bearing and race:
Front Race
Rear Race Beating Bearing
Bearing Bearing
A540HA540H
A540EA540E
Race
Bearing and race: mm (in.)
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±399
Page 658 of 2389

(c) Coat the thrust washer with petroleum jelly an(
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.
HINT: Be careful that the bearing and thrust
washer do not get out of place. (b) Coat the race and bearing with petroleum jelly and install
it onto front side of the forward clutch.
HINT: There are two different±thick races (A540H) and bear-
ings (A540E) for adjustment of the input shaft thrust play.
Bearing: A540E 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.
Bearing and race mm (in.) 23. INSTALL SECOND COAST BRAKE BAND
(a) Place the band into the case.
(b) Install the pin through the oil pump mounting bolt hole.
Bearing and race: A540H
Outer Diameter
Outer Diameter
Outer DiameterInner Diameter
Inner Diameter Inner Diameter
Front Race
mm (in.)
Thickness Thickness
mm (in.)
Rear Race BearingBearing
BearingBearing
A540H A540E
Race
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Page 659 of 2389

(b) Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the transmission
case.
NOTICE: 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±Ib, 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.)
HINT: 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.)(e) Install the direct clutch and forward clutch into the
case.
HINT: Hold the direct clutch toward the forward
clutch to prevent the thrust washer from getting
out of place.
25. INSTALL OIL PUMP INTO CASE
(a) Coat a new O±ring with ATF and install it to the oil
purnp.(f) Check the distance between the direct clutch
drum and the sun gear input drum.
Distance: Approx. 3mm (0.12 in.)
0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
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Page 660 of 2389

(b) Using SST, measure the piston stroke applying an(
releasing the compressed air (4 ± 8 kg/cm2, 57 ±
114 psi or 392 ± 785 kPa) as shown.
SST 09240±00020
Piston stroke: 2.0 ± 3.5 mm (o.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 ban(
with a new one. 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 con-
tacts the center of the second brake band de-
pression.
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.
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Page 661 of 2389
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.
NOTICE: Do not entangle the solenoid wire.
(c) Place the cover with a new gasket and gradually
tighten the bolts a little a time in sequence.
HINT: Each bolt length (mm (in.)) is indicated in
the figure.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
34. INSTALL ACCUMULATOR PISTONS AND SPRINGS
(a) Install the new O±rings to the pistons.
(b) Install the springs and pistons into the bores.
31. PLACE NEW SECOND BRAKE APPLY GASKET
32. INSTALL THROTTLE CABLE AND SOLENOID WIRE
Outer diameter
mm (in.) Free length
mm (in.) SpringColor
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Page 662 of 2389
37. INSTALL OIL TUBES
(A540E)
Using a plastic hammer, install the tubes into the position:
indicated in the figure.
(A540H)
(a) Using a plastic hammer, install the tubes into the
positions indicated in the figure.
(b) Install the bolt.
Torque: 55 kg±cm (48 in±Ib, 5.4 N±m)
HINT: Each bolt length (mm (in.)) is indicated in the figure.
NOTICE: Be careful not no bend or damage the tubes
(c)Install and tighten the ten bolts.
HINT:
wEach bolt length (mm (in.)) is indicated in the
figure.
wHand tighten the ten bolts first, then torque with
a torque wrench.
Torque: 110 kg±cm (8 ft±Ib, 11 N±m)
35. INSTALL CONNECTOR CLAMP AND TUBE RETAINER
HINT: Each bolt length (mm (in)) is indicated in the figure.
Torque: 110 kg±cm (8 ft±Ib, 11 N±m)
34. INSTALL B3 APPLY TUBE
NOTICE: Be careful not to bend or damage the tube.
36. CONNECT SOLENOID CONNECTORS
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38. 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 le-
ver.
(b) Lower the manual valve body into place.
(e¿ Hand tighten the five bolts first. Then, tighten them
with a torque wrench.
Torque: 110 kg±cm (8 ft±Ib, 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: 110 kg±cm (8 ft±Ib, 11 N±m)
HINT: 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±Ib, 10 N±m)
Oil strainer 110 kg±cm (8 ft±Ib, 11 N±m))
40. INSTALL MAGNETS IN PLACE AS SHOWN
NOTICE: 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±Ib, 4.9 N±m)
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Page 664 of 2389
46. INSTALL NEUTRAL START SWITCH
(a) Install the neutral start switch to the manual valve
shaft.
(b) Place the new locking plate and tighten the nut.
(c) Stake the nut with locking plate.
(d) Install the two bolts. 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.
(e) Install and tighten the bolt.
(e) Adjust the neutral start switch.
HINT: Align the groove and neutral basic line.
(f) Tighten the two bolts. 44. INSTALL THROTTLE CABLE RETAINING PLATE
45. INSTALL SOLENOID WIRE .
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±406