Assembly

ASSEMBLY OF TRANSMISSION
Disassembly, inspection and assembly of each component group have been indicated in the preceding information. This section deals with assembly of A140E transmission.

Before assembly, make sure again that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.

Recommended ATF type: DEXRON II

GENERAL ASSEMBLY NOTES:
1. The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Do not use adhesive cement on gaskets and similar parts.
3. Before assembling new clutch discs, soak them in automatic transmission fluid for at least two hours.
4. When assembling the transmission, be sure to use new gaskets and 0-rings.
5. Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly.
6. Dry all parts by blowing with compressed air. Never use shop rags.
7. Use petroleum jelly to keep the small parts in their places.
8. Be sure to install the thrust bearings and races in the correct direction and position.

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 the pawl.
2. INSTALL PARKING LOCK ROD

3. INSTALL PARKING LOCK PAWL BRACKET

Torque: 75 kg.cm (65 in.lb, 7.4 N.m)

4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P range.

5. INSTALL NEW GASKETS ON TRANSMISSION CASE
(a) Coat new gaskets with petroleum jelly to hold them in place.
(b) Install the overdrive brake gasket into the hole of the case.
(c) Install the overdrive clutch apply gasket into the hole of the case.

6. INSTALL OVERDRIVE UNIT OVER GASKET
Align each bolt hole in the gasket and the case. Tighten the bolts.

Torque: 250 kg.cm (18 ft.lb, 25 N.m)

7. CHECK INTERMEDIATE SHAFT END PLAY
(a) Make sure that the intermediate shaft has thrust play.

Thrust play: 0.49-1.51 mm (0.0193 - 0.0594 in.)

If the thrust play is not within specification, check the installation of intermediate shaft.
(b) Make sure that the intermediate shaft turns smoothly.

8. INSTALL FIRST AND REVERSE BRAKE IN CASE

(a) Install the inner flange facing the flat end toward you.

(b) Install in order: Disc-plate-disc-plate-disc-plate-disc- plate-disc-plate-disc.

9. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of cutouts.

10. CHECK OPERATION OF FIRST AND REVERSE BRAKE
Blow the compressed air into the oil passage with the case and be sure that the piston moves.

11. INSTALL NO.2 PLANETARY CARRIER THRUST WASHER
Coat the thrust washer with petroleum jelly and install it onto the planetary carrier.

NOTE: Make sure that the different lug shapes match the openings on the carrier.

12. INSTALL RING GEAR INTO CASE

(a) Coat the races and bearing with petroleum jelly and install them onto the ring gear.

(b) Install the ring gear into the case.

13. INSTALL REAR PLANETARY GEAR INTO CASE

(a) Align the flukes of the discs in the first and reverse brake.
(b) Align the spline of the planetary carrier with the flukes of the discs and install the planetary gear into the first and reverse brake discs.

14. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD
(a) Place the one-way clutch into the case, facing the shiny side upward.
(b) Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.
SST 09350-32013 (09351-32050)
(c) Coat the thrust washer with petroleum jelly and install it onto the planetary gear.

15. CHECK OPERATION OF NO.2 ONE-WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely clockwise and should lock counterclockwise.

16. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of cutouts.

17. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the band guide so that its tip touches the case.

18. INSTALL SECOND BRAKE INTO CASE

(a) Install the flange, facing the flat end toward you.

(b) Install in order: Disc-plate-disc-plate-disc-plate

19. INSTALL PISTON RETURN SPRING ASSEMBLY
Each spring end is installed onto the protrusion with the case.

20. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.

21. INSTALL SNAP RING
(a) Place the snap ring into the case so that the end gap is installed into the groove.
(b) While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove.
(c) Be sure the end gap of the snap ring is not aligned with one of cutouts.

22. CHECK OPERATION OF SECOND BRAKE
Blow compressed air into the oil passage with the case, and be sure that the piston moves.

23. INSTALL NEW SECOND BRAKE DRUM GASKET
Install a new drum gasket until it makes contact with the second brake drum.

24. INSTALL NO.1 ONE-WAY CLUTCH AND SECOND BRAKE HUB
(a) Align the flukes of the discs in the 2nd brake.
(b) Align the spline of the hub with the flukes of the discs and install the hub into the 2nd brake discs.

25. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the one-way clutch.

26. INSTALL FRONT PLANETARY GEAR ONTO RING GEAR
(a) Coat the races and the bearing with petroleum jelly and install them onto the ring gear.
(b) Coat the race and the bearing with petroleum jelly and install them onto the carrier.

(a) If the planetary gear and the other parts are installed correctly into the case, the end of bushing with the ring gear flange will be flush with the intermediate shaft.

(b) Coat the race with petroleum jelly and install it onto the tip of ring gear flange.
28. INSTALL INTERMEDIATE SHAFT OIL SEAL RING

29. INSTALL SECOND COAST BRAKE BAND
(a) Place the band into the case.
(b) Install the pin through the oil pump mounting bolt hole.

30. INSTALL FORWARD CLUTCH INTO CASE
(a) Coat the races and bearings with petroleum jelly and install them onto both sides of the clutch drum.
(b) Coat the clutch drum thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.

(d) Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.
(e) If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surface of the forward clutch.

(f) Place the direct clutch and forward clutch into the case.
(g) While rotate the forward clutch to mesh the front planetary ring gear and discs.

(h) Check the distance between the A and B as shown in the illustration.

Distance: Approx. 3 mm (0.118 in.)

31. INSTALL OIL PUMP INTO CASE
(a) Coat the race with petroleum jelly and install it onto stator shaft.

NOTE: After installing the oil pump, measure the input shaft thrust play.

If the thrust play is greater than standard, select and insert one of the two different size races.
(b) Place the oil pump through the input shaft, and align the bolt holes of the pump body at the transmission case.

(c) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.

(d) Install the seven bolts.

Torque: 225 kg.cm (16 ft.lb, 22 N.m)

32. MEASURE THRUST PLAY OF INPUT SHAFT

Measure the thrust play.

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)

NOTE: There are two different thickness of races for the end of stator shaft. If necessary, select one of them.

Race thickness: 0.8 mm (0.031 in.) 1.4 mm (0.055 in.)

33. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.

34. INSTALL SECOND COAST BRAKE PISTON
(a) Install the outer spring with the piston.
(b) Place the cover into the bore.
(c) Using SST, install the snap ring while pressing the cover.
SST 09350-32013 (09351-32050)
(d) Check that the front end of the piston rod contacts the center of the second brake band depression.

35. CHECK SECOND COAST BRAKE PISTON STROKE

(a) Apply a small amount of paint to the piston rod at the point it meets the case as shown in the illustration.

(b) Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/cm2, 57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240-00020

Piston stroke: 1.5-3.0 mm (0.059 - 0.118 in.)

If the stroke is more than standard value, replace the piston rod with a longer one.

Piston rod length: 72.9 mm (2.870 in.) 71.4 mm (2.811 in.)

Re-measure the stroke. If it is still more than standard value, replace the brake band with a new one.

36. INSTALL ACCUMULATOR PISTONS AND SPRINGS

(a) Install the springs and pistons into the bore.

(b) Place the cover with the gasket and tighten the bolts gradually in sequence.

NOTE: Each bolt length (mm) is indicated in the figure.

37. INSTALL NEW SECOND BRAKE APPLY GASKET

38. INSTALL THROTTLE CABLE AND SOLENOID WIRING IN CASE
Push them through the case, being careful not to damage the 0-ring. Check for full seating.

CAUTION: In subsequent work, do not roll the case over the cable and break the cable fitting.

39. PLACE VALVE BODY ON TRANSMISSION
(a) While holding the cam down with your hand, slip the cable end into the slot.
(b) Lower valve body into place.

CAUTION: Do not entangle the throttle cable.

40. INSTALL BOLTS IN VALVE BODY
(a) Finger tighten the twelve bolts first, then tighten them with torque wrench.

Torque: 100 kg.cm (7ft.lb, 10 N.m)

NOTE: Each bolt length (mm) is indicated in the figure.

41. CONNECT SOLENOIDS WIRING
(a) Connect the No. 1 solenoid connector. (white and shorter wire)
(b) Connect the No. 2 solenoid connector. (black and longer wire)

42. PLACE MANUAL VALVE AND BODY ON TRANSMISSION
(a) Align the manual valve with the pin on the manual valve lever.
(b) Lower the manual valve body into place.
(c) Finger tighten the four bolts first. Then tighten them with a torque wrench.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)

NOTE: Each bolt length (mm) is indicated in the figure.

43. INSTALL DETENT SPRING
(a) Finger tighten the two bolts first. Then tighten them with a torque wrench.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)

NOTE: Each bolt length (mm) is indicated in the figure.

(b) Check that the manual valve lever is touching the center of the detent spring tip roller.

44. INSTALL OIL TUBES
Using a plastic hammer, install the tubes into the positions indicated in the figure.

CAUTION: Be careful not to bend or damage the tubes.

45. INSTALL TUBE BRACKET
Each bolt length (mm) is indicated in the figure.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)

46. INSTALL OIL STRAINER
Each bolt length (mm) is indicated in the figure.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)

47. INSTALL MAGNET IN PLACE AS SHOWN

CAUTION: Make sure that the magnet does not interfere with the oil tubes.

48. INSTALL OIL PAN WITH GASKET

Torque: 50 kg.cm (43 in.lb, 4.9 N.m)

49. INSTALL SPEED SENSOR
(a) Install the speed sensor with a new 0-ring.
(b) Install the cover bracket with the two bolts.

50. INSTALL RETAINING PLATES
(a) Install the solenoid wiring retaining plate.
(b) Install the throttle cable retaining plate.
51. INSTALL FELLER TUBE AND FELLER GAUGE

52. INSTALL SOLENOID
(a) Coat a new 0-ring with ATF and push the tip of solenoid into the hole.
(b) Tighten the two bolts evenly and gradually.

53. INSTALL NEUTRAL START SWITCH
(a) Install the seal gasket, facing the lip inward.
(b) Tighten the nut and stake it with the lock washer.

Torque: 70 kg.cm (61 in.lb, 6.9 N.m)

54. INSTALL MANUAL SHIFT LEVER

55. ADJUST NEUTRAL START SWITCH
(a) Align the groove and neutral basic line.
(b) Lock the switch with two bolts.

Torque: 55 kg.cm (48 in.-lb, 5.4 N.m)

56. INSTALL THE TWO OIL COOLER PIPES
(a) Install the bracket onto the case.
(b) Connect the pipes to the union.
(c) Clamp the two pipes onto bracket.
(d) Tighten the union nuts.

Torque: 350 kg.cm (25 ft.lb, 34 N.m)