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AT4416
Dust Deflector Extension
Housing
AT4414
Speed Sensor
AT4415
Dynamic Damper
AT4417
SST
AT4309
DISASSEMBLY OF COMPONENT PARTS
1. REMOVE TRANSFER MODE SELECT LEVER AND
ROD
2. REMOVE REAR WHEEL SPEED SENSOR
(a) Remove the bolt and pull out the speed sensor.
(b) Remove the O-ring from speed sensor.
3. REMOVE DYNAMIC DAMPER
Remove the four bolts and dynamic damper.
4. REMOVE EXTENSION HOUSING
(a) Remove the dust deflector from the extension
housing.
(b) Remove the four bolts and extension housing.
(c) Remove the O-ring from the extension housing.
(d) Using SST, remove the oil seal.
SST 09308-00010
- TRANSFER (A540H)Disassembly of Component PartsTF-3
Page 198 of 2389

AT4617
AT4416
Extension
Housing Dust Deflector
AT4415Dynamic Damper
AT4414
Speed Sensor
AT4333
(b) Install the right case retainer to the transfer right
case.
(c) Install and torque the five bolts.
Torque: 300 kg-cm (22 ft-lb, 29 N-m)
20. INSTALL EXTENSION HOUSING
(a) Using SST and a hammer, drive in a new oil seal
as shown.
SST 09325-20010
(b) Coat the lip of the oil seal with MP grease.
(c) Coat a new O-ring with gear oil and install it to
the extension housing.
(d) Install the extension housing to the driven pinion
bearing cage.
(e) Install and torque the four bolts.
Torque: 260 kg-cm (19 ft-lb, 25 N-m)
(f) Using a plastic hammer, install the dust deflector.
21. INSTALL DYNAMIC DAMPER
Install and torque the four bolts.
Torque: 260 kg-cm (19 ft-lb, 25 N-m)
22. INSTALL REAR WHEEL SPEED SENSOR
(a) Install a new O-ring to the speed sensor.
(b) Install the speed sensor to the transfer left case.
(c) Install and torque a bolt.
Torque: 55 kg-cm (48 in.-lb, 5.4 N-m)
TF-38- TRANSFER (A540H)Assembly of Component Parts
Page 585 of 2389
4. REMOVE EXTENSION HOUSING
(a) Remove the dust deflector from the extension housing.
(b) Remove the four bolts and extension housing.
(c) Remove the O±ring from the extension housing. 3. REMOVE DYNAMIC DAMPER
Remove the four bolts and dynamic damper.
REMOVAL OF COMPONENT PARTS
7. REMOVE TRANSFER MODE SELECT LEVER AND ROD
2: REMOVE REAR WHEEL SPEED SENSOR
(a) Remove the bolt and pull out the speed sensor.
(b) Remove the O±ring from speed sensor.
(d) Using SST, remove the oil seal.
SST 09308±00010
± AUTOMATIC TRANSAXLEComponent Parts (Transfer A540M)AT±344
Page 635 of 2389
(c) Coat a new O±ring with gear oil and install it to the
extension housing.
(d) Install the extension housing to the driven pinion
bearing cage.
(e) Install and torque the four bolts.
Torque: 260 kg±cm (19 ft±Ib, 25 N±m)
(f) Using a plastic hammer, install the dust deflector. 20. INSTALL EXTENSION HOUSING
(a) Using SST and a hammer, drive in a new oil seal as shown.
SST 09325±20010
(b) Coat the lip of the oil seal with MP grease.
22. INSTALL REAR WHEEL SPEED SENSOR
(a) Install a new O±ring to the speed sensor.
(b) Install the speed sensor to the transfer left case.
(c) Install and torque a bolt.
Torque: 55 kg±cm (48 in.±Ib, 5.4 N±m)
(b) Install the right case retainer to the transfer right
case.
(c) Install and torque the five bolts.
Torque: 300 kg±cm (22 ft±lb, 29 N±m)
21. INSTALL DYNAMIC DAMPER
Install and torque the four bolts.
Torque: 260 kg±cm (19 ft±lb, 25 N±m)
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±379
Page 870 of 2389
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the cylinder inspection
hole and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)
4. REMOVE FOLLOWING PARTS:
(a) Two anti±squeal springs.
(b) Two brake pads
(c) Two or four anti±squeal shims
(d) Two pad wear indicator plates
(e) Four pad support plates 1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the rotor disc
with the hub nuts.
(b) Remove the brake cylinder and suspend it so the hose
is not stretched.
HINT: Do not disconnect the brake hose. 3. REMOVE CYLINDER FROM TORQUE PLATE
(a) Remove two installation bolts from the torque plate.
± BRAKE SYSTEMFront BrakeBR±19
Page 872 of 2389
REMOVAL OF CYLINDER
(See page BR±18)
1. DISCONNECT BRAKE LINE
Remove the union bolt and disconnect the brake line. Use
a container to catch the brake fluid.(d) Install and torque two installation bolts.
Torque: 400 kg±cm (29 ft±Ib, 39 N¿m)
10. INSTALL FRONT WHEEL
11. CHECK THAT FLUID LEVEL IS MAX LINE
2. REMOVE CYLINDER FROM TORQUE PLATE
Remove the two installation bolts and cylinder.
3. REMOVE PADS
(See step 4 on page BR±19)
± BRAKE SYSTEMFront BrakeBR±21
Page 879 of 2389
2. MEASURE BRAKE SHOE LINING THICKNESS
Standard thickness: 5.0 mm (0.197 in. )
Minimum thickness: 1 .0 mm (0.039 in.)
If the shoe lining is less than minimum or shows signs of
uneven wear, replace the brake shoes.
HINT: If any of the brake shoes have to be replaced, re-
place all of the rear shoes in order to maintain even brak-
ing. 9. IF NECESSARY, DISASSEMBLE WHEEL CYLINDER
Remove the following parts from the wheel cylinder.
wTwo boots
wTwo pistons
wTwo piston cups
wSpring _
3. MEASURE BRAKE DRUM INSIDE DIAMETER
Standard inside diameter: 228.6 mm (9.000 in.)
Maximum inside diameter: 230.6 mm (9.079 in.)
If the drum is scored or worn, the brake drum may be lathed
to the maximum inside diameter.
INSPECTION AND REPAIR OF REAR
BRAKE COMPONENTS
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage. 8. REMOVE WHEEL CYLINDER
Remove the two bolts and the wheel cylinder.
± BRAKE SYSTEMRear BrakeBR±28
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1. ASSEMBLE WHEEL CYLINDER
(a) Apply lithium soap base glycol grease to the cups
and pistons as shown.
(b) Assemble the wheel cylinder.
HINT: Install in proper direction only.
wSpring
wTwo cups
wTwo pistons
wTwo boots .
2. INSTALL WHEEL CYLINDER
Install the wheel cylinder on the backing plate with two
bolts.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
INSTALLATION OF REAR BRAKE
(See page BR±26)
HINT: Assemble the parts in the correct direction as
shown.
3. CONNECT BRAKE TUBE TO WHEEL CYLINDER
Using SST, connect the brake tube.
SST 09751±36011
Torque: 155 kg±crn (11 ft±Ib, 15 N±m)
± BRAKE SYSTEMRear BrakeBR±30