Part 1
Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. This chapter 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(R) II.
GENERAL ASSEMBLY NOTE:
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 O-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
c. Install the outer flange, facing the flat end toward the piston side.
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. INSPECTION DISCS
19. 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
20. INSTALL PISTON RETURN SPRING ASSEMBLY
Each spring end is installed onto the protrusion with the case.
21. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.
22. 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.
23. CHECK OPERATION OF SECOND BRAKE
Blow compressed air into the oil passage with the case, and be sure that the piston moves.
24. INSTALL NEW SECOND BRAKE DRUM GASKET
25. INSTALL N0.1 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.
26. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the one-way clutch.
27. 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.
c. Install the planetary gear onto the ring gear.
28. INSTALL FRONT PLANETARY GEAR ASSEMBLY ONTO SUN GEAR
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.
29. INSTALL INTERMEDIATE SHAFT OIL SEAL RING
30. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.