Page 137 of 2389
AT5039
mm (in.)
A540E
ABCDEF
Bearing
(with race)Outer
DiameterSee page
AT-35447.6
(1.874)45.5
(1.791)
u38.7
(1.524)54.0
(2.126)
Inner
Diameter27.7
(1.091)31.4
(1.236)30.1
(1.185)u22.6
(0.890)39.4
(1.551)
A540H A'
B' C' D' E' F'
Front
Bearing
RaceOuter
Diameter43.0
(1.693)37.9
(1.492)u45.0
(1.772)37.3
(1.469)
Inner
Diameter30.5
(1.201)22.0
(0.866)u28.0
(1.102)24.1
(0.949)
Thrust
BearingOuter
Diameter42.0
(1.654)36.1
(1.421)u45.0
(1.772)37.6
(1.480)46.3
(1.823)
Inner
Diameter28.9
(1.138)22.2
(0.874)
u30.0
(1.181)24.0
(0.974)26.2
(1.031)
Rear
Bearing
RaceOuter
Diameter42.0
(1.654)35.7
(1.406)35.0
(1.378)37.6
(1.480)43.0
(1.693)
Inner
Diameter27.1
(1.067)23.0
(0.906)19.0
(0.748)22.2
(0.874)24.5
(0.965)
8. Be sure to install the thrust bearings and races in the correct direction and position.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-121
Page 138 of 2389
AT3691
A540E
AT3692
AT3595
SST
AT3594
A540E
AT3605
INSTALLATION OF DIFFERENTIAL AND
DRIVE PINION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
(a) Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with the
pinion shaft. (A540E)
(b) Install the two new O-rings to the bearing cage.
(A540E)
(c) Coat the O-rings with ATF. (A540E)
(d) Using a hammer and brass bar, slightly tap the
bearing cage into the transaxle case until the
snap ring groove in the bore can be seen.
(e) Using SST, install snap ring into the bore.
SST 09350-32014 (09351-32050)
2. (A540E)
PLACE SENSOR ROTOR ONTO DRIVE PINION SHAFT
AT-122- AUTOMATIC TRANSAXLEInstallation of Component Parts
Page 139 of 2389
AT3593
Oil SlingerSpacer
AT3693
Outer Race SSTSST
AT3694
SST (a) SST (b) Counter
Drive Gear
AT3695
SST
AT4175
Spacer A540H3. (A540H)
INSTALL DRIVE PINION BEARING NO. 2 SPACER
4. PLACE OIL SLINGER AND NEW SPACER
HINT: Install the spacer with the small end downward.
5. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350-32014 (09351-32100, 09351-32140)
6. INSTALL COUNTER DRIVEN GEAR
(a) Place SST into the transaxle hole to hold the drive
pinion shaft.
SST (a) 09350-32014 (09351-32130, 09351-32150)
(b) Using SST, press in the counter driven gear until
slightly thickness between the counter driven gear
bearing and outer race.
SST (b) 09350-32014 (09351-32140)
7. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION
PRELOAD
(a) Install the new lock nut.
(b) Using SST to hold the gear, tighten the nut.
Torque: 2,100 kg-cm (152 ft-lb, 206 N-m)
SST 09330-00021, 09350-32014 (09351-32032)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-123
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AT3989
AT3697
Shim Outer Race A540E
AT3585
A540E
AT3588
(c) Turn the gear counterclockwise and clockwise sev-
eral times.
(d) Using a torque meter, measure the preload of the
drive pinion.
Drive pinion preload (at starting):
New bearing
10 - 16 kg-cm
(8.7 - 13.9 in.-lb, 1.0 - 1.6 N-m)
Reused bearing
5 - 8 kg-cm
(4.3 - 6.9 in.-lb, 0.5 - 0.8 N-m)
If the preload is greater than specified,
replace the bearing spacer.
If the preload is less than specified, retigh-
ten the nut 130 kg-cm (9 ft-lb, 13 N-m) at
a time until the specified preload is
reached.
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 3,600 kg-cm (260 ft-lb, 353 N-m)
(e) If the preload is adjusted within specification, make
a note of it.
(f) Stake the lock nut.
8. (A540E)
PLACE OUTER RACE AND SHIM ONTO RH SIDE
BEARING
9. PLACE DIFFERENTIAL CASE INTO TRANSAXLE
CASE
(A540E)
Be sure to install the shim and outer race into place.
AT-124- AUTOMATIC TRANSAXLEInstallation of Component Parts
Page 141 of 2389
AT3698
Seal
Packing A540E
AT4577
A540H
AT4601
A540H
AT3583
A540E
AT4965
Sleeve A540H(A540H)
Be sure to install the ring gear mount case sleeve and
outer race into place.
10. INSTALL CARRIER COVER
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the carrier
cover and transaxle case.
(b) Apply seal packing to the carrier cover as shown.
Seal packing: Part No. 08826-00090, THREE BOND
1281 or equivalent
HINT: Install the carrier cover within ten minutes after
applying seal packing.
(c) Install the two apply gaskets.
(d) Install and torque the eleven bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-125
Page 142 of 2389

New BearingReused Bearing
A540E2.8 - 4.4
(2.4 - 3.8, 0.3 - 0.4)1.4 - 2.2
(1.2 - 1.9, 0.1 - 0.2)
A540H2.3 - 3.7
(2.0 - 3.2, 0.2 - 0.4)1.2 - 1.9
(1.0 - 1.6, 0.1 - 0.2)
AT4170
AT4171
AT3700
Adjusting Shim
MarkThicknessMarkThickness
0
1
2
3
4
5
6
7
82.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)
2.35 (0.0925)
2.40 (0.0945)9
A
B
C
D
E
F
G
H2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)
2.70 (0.1063)
2.75 (0.1083)
2.80 (0.1102)
2.85 (0.1122)
A540H
AT4173
mm (in.)
11. ADJUST SIDE SEARING PRELOAD
(a) Remove any packing material on the contacting
surfaces of the LH bearing retainer and transaxle
case.
HINT: Do not apply seal packing yet.
(b) Install the LH bearing retainer and torque the six
bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(c) Snap down the bearings by turning the differential
case several times.
(d) Using a torque meter, measure the differential total
preload.
Total preload (at starting)
Add drive pinion preload
kg-cm (in.-lb, N-m)
If the preload is not within specification, replace the
adjusting shim in the LH bearing retainer with another
thickness one.
AT-126- AUTOMATIC TRANSAXLEInstallation of Component Parts
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AT4563
AT3711
AT3712
SST
AT4170
12. INSTALL LH BEARING RETAINER
(a) Remove the six bolts and LH bearing retainer.
(b) Remove any packing material on the contacting
surfaces of LH bearing retainer, transaxle case
and carrier cover.
(c) Apply the seal packing to the transaxle case and
carrier cover as shown.
Seal packing: Part No. 08826 - 00090, THREE
BOND 1281 or equivalent
HINT: Install the LH bearing retainer with ten minutes
after applying seal packing.
(d) Install the LH bearing retainer.
(e) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND
1324 or equivalent
(f) Tighten the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(g) Snap down the bearings.
(h) Recheck the differential total preload.
AT4170
13. INSTALL NEW OIL SEAL
(a) Place the oil baffle onto the LH bearing retainer.
(b) Using SST, driven in a new oil seal until its end is
flush with the surface of the LH bearing retainer.
SST 09223-15010
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-127
Page 144 of 2389
AT3581
A540E
AT3586AT3713
Seal
Packing A540E
14. (A540E)
INSTALL RH RETAINER
(a) Remove any packing material on the contacting
surfaces of RH retainer and transaxle case.
(b) Apply the seal packing to the RH retainer as
shown.
Seal packing: Part No. 08826-00090, THREE BOND
1281 or equivalent
HINT: Install the RH retainer within ten minutes after
applying seal packing.
(c) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324
or equivalent
(d) Tighten the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
15. INSTALL DRIVE PINION CAP
(a) Install a new O-ring to the cap.
(b) Install the drive pinion cap to the transaxle case.
AT-128- AUTOMATIC TRANSAXLEInstallation of Component Parts