Part 2

15. INSTALL REAR PLANETARY GEAR INTO CASE




a. Align the flukes of the discs in the first and reverse brake.




b. Coat the thrust washer with petroleum jelly. Align the tab of the washer with the hollow of the carrier.
c. Align the spline of the planetary carrier with either of the flukes of the discs, and install the planetary gear into the first and reverse brake discs.

16. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD




a. Place the one-way clutch with the shiny side upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.

SST 09350-32014 (09351-32050)




c. Coat the thrust washer with petroleum jelly and install it onto the planetary gear.




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




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




19. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the two band guides so that its tip touches the case.




20. INSTALL SECOND BRAKE INTO CASE
a. Install the flange, facing the flat end toward the oil pump side.
b. Install the discs and plates.

Install in order: P = Plate D = Disc
Flange-D-P-D-P-D-P




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




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




23. 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 the cutouts.




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




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

26. 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 to the 2nd brake discs.




c. Check the distance between the surfaces of the 2nd brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 in.)




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

28. INSTALL FRONT PLANETARY GEAR ONTO RING GEAR







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







b. Coat the race and bearing with petroleum jelly, and install them onto the planetary gear.




c. Install the planetary gear onto the ring gear.

29. INSTALL FRONT PLANETARY GEAR ASSEMBLY ONTO SUN GEAR




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




b. Coat the race with petroleum jelly and install it onto the tip of ring gear flange.

Race: Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.)




30. INSTALL INTERMEDIATE SHAFT OIL SEAL RING




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

32. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH













a. Coat the races and bearing 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.




c. Align the flukes of discs in the direct clutch.




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. 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 (0.116 in.)

33. INSTALL OIL PUMP INTO CASE




a. Coat the race with petroleum jelly and install it onto stator shaft.




b. Coat a new O-ring with ATF and install it to oil pump.




c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. 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.

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




e. Install and tighten the seven bolts.

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




34. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.

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

HINT: There are two thickness of races for the end of stator shaft.

If the thrust play is in excess of standard, select one of them.

Race thicknesses: 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. Coat the new O-rings with ATF and install them on 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 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 shown 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) 71.4mm(2.811 in)

38. 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.

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




39. INSTALL NEW SECOND BRAKE APPLY GASKET
40. (A140L)
INSTALL NEW GOVERNOR OIL STRAINER




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

NOTE: In subsequent work, to avoid breaking the cable fitting do not roll the case over the cable.





42. (A140E)
INSTALL SOLENOID WIRING

(A140L)
INSTALL KICK-DOWN SWITCH WIRING
Push the solenoid wiring through the case, being careful not to damage the O-ring. Check for full seating.




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

NOTE: Do not entangle the kick-down switch wire or solenoid wire.







44. INSTALL BOLTS IN VALVE BODY

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

Hand tighten the twelve bolts (A140E) or fourteen bolts (A140L) first, then torque with a torque wrench.

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




45. (A140E)
CONNECT SOLENOID WIRING
a. Connect the No. 1 solenoid connector. (white and shorter wire)
b. Connect the No. 2 solenoid connector. (black and longer wire)




46. (A1401)
CONNECT KICK-DOWN SWITCH WIRING
Connect the kick-down switch connector and clamp it onto the bracket.

47. 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 lever.
b. Lower the manual valve body into place.
c. Hand tighten the four bolts first. Then, tighten them with a torque wrench.

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




d. Place the detent spring on the manual valve body and hand tighten the two bolts first. Then, tighten them with a torque wrench.

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

e. Check that the manual valve lever is touching the center of the detent spring tip roller.




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

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




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

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