Part 3

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.




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: 2.0 - 3.5 mm (0.079 - 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 band with a new one.

30. INSTALL ACCUMULATOR PISTONS AND SPRINGS




a. Install the new O-rings to the pistons.




b. Install the springs and pistons into the bores.




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-lb, 10 N.m)




31. PLACE NEW SECOND BRAKE APPLY GASKET




32. INSTALL THROTTLE CABLE AND SOLENOID WIRE
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.

NOTE: Do not entangle the solenoid wire.




c. Install and tighten the ten bolts.

HINT:
- Each bolt length (mm (in.)) is indicated in the figure.
- Hand tighten the ten bolts first, then torque with a torque wrench.

Torque: 110 kg-cm (8 ft-lb, 11 N.m)




34. INSTALL B(3) APPLY TUBE

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




35. INSTALL CONNECTOR CLAMP AND TUBE RETAINER

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

Torque: 110 kg-cm (8 ft-lb, 11 N.m)




36. CONNECT SOLENOID CONNECTORS




37. INSTALL OIL TUBES

(A540E)
Using a plastic hammer, install the tubes into the positions 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-lb, 5.4 N.m)

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

NOTE: Be careful not no bend or damage the tubes

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

Torque: 110 kg-cm (8 ft-lb, 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-lb, 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-lb, 10 N.m)
Oil strainer 110kg-cm (8 ft-lb, 11 N.m)

40. INSTALL MAGNETS IN PLACE AS SHOWN

NOTE: 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-lb, 4.9 N.m)




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.
c. Install and tighten the bolt.




44. INSTALL THROTTLE CABLE RETAINING PLATE
45. INSTALL SOLENOID WIRE
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.




e. Adjust the neutral start switch.

HINT: Align the groove and neutral basic line.

f. Tighten the two bolts.




47. INSTALL MANUAL SHIFT LEVER
48. INSTALL UNION AND ELBOW




a. Install the new O-rings to the union and elbow.
b. Install the union and elbow to the transaxle case.

Torque: 275 kg-cm (20 ft-lb, 27 N.m)






HINT: Install the elbow at right angles to the bottom of the transaxle case.

49. (A540H)
INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT




a. Install a new snap ring to the shaft groove.
b. Using a plastic hammer, install the shaft.






HINT: Keeping the intermediate shaft on the pinion shaft of differential, measure the point in the illustration.

Protrusion length (Reference): 255.5 mm (10.059 in.)




50. (A540H) INSTALL APPLY GASKET
Install a new apply gasket to the differential carrier cover

51. (A540H)
INSTALL TRANSFER ASSEMBLY




a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transfer and transaxle.
b. Apply seal packing to the transaxle as shown in the illustration.

Seal packing: Part No.08883-00090, Adhesive 1131, THREE BOND 1131, Loctite 518, or equivalent

HINT: Install the transfer assembly as soon as the seal packing is applied.




c. Coat the threads of bolts with sealer.

Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent.

d. Install and torque the five nuts and three bolts.

Torque: 700 kg-cm (51 ft-lb, 69 N.m)




52. (A540H)
INSPECT MODE SELECT LEVER POSITION
After finishing inspection or repair the transaxle, be sure the select lever position to FREE mode and attach the lock bolt.