Part 2

31. 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. Align the flukes of the discs in the forward clutch.
c. Hold the sun gear input drum and rotate the input shaft to mesh the hub with the clutch discs of the forward clutch.

NOTE: Align the center of the input shaft and intermediate shaft, and while pushing on the input shaft, rotate to mesh the hub and discs.




d. If the flukes of the discs are meshed with the hub correctly, the protrusion of the forward clutch drum will have entered deeper than the tip of the sun gear input drum.

32. INSTALL DIRECT CLUTCH INTO CASE



a. Coat the clutch drum thrust washer with petroleum jelly and install it facing the oil groove upward onto the drum.
b. Align the flukes of discs in the direct clutch.




c. Hold the input shaft, and put the direct clutch drum through the 2nd coast brake band.
d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.
e. Check the distance between the direct clutch and forward clutch.

Distance: Approx. 3 mm (0.12 in.)




33. 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)




34. 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.)




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




36. 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 O935O - 32O13 (09351-32050)
d. Check that the front end of the piston rod contacts the center of the second brake band depression.

37. 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 show in the illustration.




b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 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.




38. CHECK OPERATION OF SECOND COAST BRAKE
Apply the compressed air into the hole with the case and make sure that the piston rod moves.







39. 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.




40. INSTALL NEW SECOND BRAKE APPLY GASKET (GOVERNOR APPLY GASKET) AND GOVERNOR OIL STRAINER

NOTE: Governor oil strainer A140L only




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

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




42. 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.

43. INSTALL BOLTS IN VALVE BODY



a. [A140E] Finger tighten the twelve bolts first, then tighten them with torque wrench.




b. [A140L] Finger tighten the fourteen bolts first, then tighten them with torque wrench.

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

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




44. [A140E] 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)




45. 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.




46. 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.




47. 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.




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

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




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

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




50. INSTALL MAGNETS IN PLACE AS SHOWN

CAUTION: Make sure that the magnets do not interfere with the oil tubes.




61. INSTALL OIL PAN WITH GASKET

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




52. (A140E) INSTALL SPEED SENSOR
a. Install the speed sensor with a new O-ring.
b. Install the cover bracket with the two bolts.




53. (A140L) INSTALL GOVERNOR BODY
a. Install the governor body adaptor.
b. Install the thrust washer onto the governor body
c. Install the governor body with the plate washer
d. Install the cover over a new O-ring.
e. Install the cover bracket with the two bolts.




54. INSTALL RETAINING PLATES
a. Install the solenoid wiring retaining plate.
b. Install the throttle cable retaining plate.

55. INSTALL FILLER TUBE AND FILLER GAUGE




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




57. 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)

58. INSTALL MANUAL SHIFT LEVER




59. 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)




60. INSTALL 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)