Part 3

61. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH

a. Coat the race and bearing with petroleum jelly, and install them onto the forward clutch drum.

b. Coat the clutch drum thrust washer with petroleum jelly, and install it onto the direct clutch drum with the oil groove facing upward.

c. Using a screwdriver, 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.

HINT: 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 surfaces of the forward clutch.

e. Place the direct clutch and forward clutch into the case.
f. While rotating the forward clutch to mesh the front planetary ring gear and discs, install them.

g. Check the distance between A and B shown in the illustration.

Distance: Approx. 3 mm (0.118 in.)

62. INSTALL DIFFERENTIAL
63. INSTALL TRANSAXLE HOUSING

a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transmission case.
b. Apply seal packing to the transaxle housing as shown.

Seal packing: Part No.08833-00090, THREE BOND 1131, LOCTITE 518 or equivalent.

c. Apply sealant to the bolt threads.

Sealant: Part No.08833-00080, Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent

d. Install and tighten the bolts.

Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

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

64. CHECK PRELOAD OF DIFFERENTIAL SIDE BEARING
65. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto the stator shaft.

Race:
Outer diameter 43.0 mm (1.693 in.)
Inner diameter 30.5 mm (1.201 in.)

b. Coat the new O-ring with ATF, and install it to pump body.

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 six bolts.

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)

66. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play in axial direction.

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

If the play is not as specified, select and replace the race for the end of stator shaft.

HINT: There are two different thickness of races. If necessary, select one of them.

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

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

68. INSTALL SECOND COAST BRAKE PISTON

a. Install the two new O-ring to the cover.

HINT: Coat the O-ring with ATF before installing.

b. Install the spring, piston and cover into the bore

c. Using SST, install the snap ring while pressing the cover.

SST 09350-31014 (09351-32050)

d. Check that the front end of the piston rod contacts the center of the second brake band depression.

69. MEASURE PISTON STROKE OF SECOND COAST BRAKE

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 (392 - 785 kPa, 4 - 8 kg/sq.cm, 57 - 114 psi) as shown.

SST 09240-00020

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

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

70. INSTAL ACCUMULATOR PISTONS AND SPRINGS
a. Coat the new O-rings with ATF, and install them to the pistons.

A241E,A243L:

A241E:

A243L:

A240L:

b. Install the pistons and springs to the case.
c. Place the cover with a new gasket and gradually tighten the bolts little a time in sequence.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

71. INSTALL SECOND BRAKE APPLY GASKET

72. INSTALL THROTTLE CABLE IN CASE
Push the cable through the hole on 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.

73. INSTALL SOLENOID WIRE
74. INSTALL VALVE BODY

a. Coat the manual valve with ATF and install it to the valve body.

b. Connect the connecting rod to the manual valve lever.

c. Place the valve body on the transmission.
d. While holding the cam down with your hand, slip the cable end into the slot.

A241E:

A240L,A243L:

e. Install the twelve bolts and wire retainer shown in the illustration, and hand tighten all the bolts first. Then tighten them with a torque wrench.

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

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

A243L,A240L:

A241E:

75. CONNECT SOLENOID CONNECTOR

76. INSTALL MANUAL DETENT SPRING
a. Install the detent spring and cover in place, and install the bolt (length: 16 mm).
b. Hand tighten the bolt first, then tighten the bolt with a torque wrench.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

c. Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.

77. INSTALL OIL TUBES

a. Tap the tubes with a plastic hammer to install them into the positions indicated in the illustration.

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

b. Install the oil tube clamp and bracket.

HINT: Each bolt length (mm) is indicated in the illustration. Hand tighten all bolts first, then tighten them with a torque wrench.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

78. INSTALL OIL STRAINER

a. Install the new gasket to the oil strainer.

b. Install the oil strainer with the three bolts.

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

79. INSTALL THREE MAGNETS IN OIL PAN

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

80. INSTALL OIL PAN

a. Install a new gasket to the oil pan and install them to the transmission.
b. Tighten the eighteen bolts.

Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)

c. Install a new gasket to the drain plug and install it to the oil pan.

Torque: 17 N.m (175 kgf.cm, 13 ft.lbf)

81. (A241E)
INSTALL SPEED SENSOR AND SENSOR ROTOR

a. Install the sensor adaptor with three bolts.

b. Install the sensor rotor.

c. Install a new O-ring to the sensor cover.

d. Install the sensor cover to the transmission and then install the sensor cover bracket with the two bolts.

Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

e. Coat a new O-ring with ATF and install it to the speed sensor.
f. Install the speed sensor and retaining plate.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

82. (A240L, A241E, A243L)
INSTALL GOVERNOR BODY

a. Install the governor oil strainer to the case.

b. Install a new gasket to governor body adaptor.
c. Install the governor body adaptor with three bolts.

d. Install the governor body and thrust washer.

e. Install a new O-ring to the cover.

f. Install the cover to the transmission and then install the two cover brackets with the two bolts.

Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

83. INSTALL SOLENOID WIRE RETAINING PLATE
Install the retaining plate with the bolt.

84. INSTALL THROTTLE CABLE RETAINING PLATE
Install the retaining plate with the bolt.

85. INSTALL NEUTRAL START SWITCH

a. Install the neutral start switch to the manual valve shaft.
b. Install the packing. (A240L, A241E)
c. Install the nut and lock stopper.
d. Tighten the nut.

Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf)

e. Temporarily install the manual shift lever.
f. Turn the lever counterclockwise until it stops, then turn it clockwise two notches.
g. Remove the manual shift lever.

h. Align the groove and neutral basic line as shown.
i. Install and tighten the two bolts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

j. Using a screwdriver, stake the nut with the nut stopper.

k. Install the manual shift lever with the washer, and tighten the nut.

86. INSTALL FILLER TUBE AND TRANSMISSION DIPSTICK
87. INSTALL TWO OIL COOLER PIPES