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AT7774
SST
AT7775
Fulcrum
Length
SST
AT7776
SST
AT7773
3. INSTALL SPACER
Install a new spacer to the driven pinion.
4. INSTALL DRIVEN PINION REAR SIDE BEARING
(a) Install the bearing cage to the driven pinion.
(b) Using a press and SST, install the rear side bearing
to the driven pinion.
SST 09506-35010
5. ADJUST DRIVEN PINION PRELOAD
(a) Using SST, torque a new nut.
SST 09326-2001 1
Torque: 1,000 kg-cm (72 ft-lb, 98 N-m)
HINT: Use a torque wrench with a fulcrum length of
42.5 cm (16.732 in.).
(b) Using a spring tension gauge and SST, measure
the preload.
SST 09326-2001 1
HINT: Turn the driven pinion right and left two or three
times to allow the bearings to settle.
Preload (at starting):
New bearing
1.8 - 2.9 kg (4.0 - 6.4 lb, 18 - 28 N)
Reused bearing
0.9 - 1.4 kg (2.0 - 3.1 lb, 9 - 14 N)
If preload is greater than specification, replace
the bearing spacer.
If preload is less than specification, retighten
the nut 5° - 10°at a time until the specified
preload is rechecked.
If the maximum torque is exceeded while retightening
the nut, replace the bearing spacer and repeat the pre-
load procedure.
Do not back off the pinion nut to reduce the preload.
Maximum torque: 2,400 kg-cm (174 ft-lb, 235 N-m)
NOTICE: Using the soft jaws, hold the bearing cage in
a vise.
- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)TF-9
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AT7777
6. STAKE LOCK NUT
Using a pin punch and hammer, stake the nut.
TF-10- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)
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AT4313
AT4312
r Non-reusable partr Oil Seal Differential
Side Gear Shaft
Holder Hole Snap RingTransfer Right Case
Retainer r Oil SealShaft Snap Ring Holder Bearing
Transfer Right Case Retainer
COMPONENTS
AT4324
DISASSEMBLY OF TRANSFER RIGHT CASE
RETAINER
1. REMOVE OIL SEAL
Using a screwdriver, remove the oil seal.
2. REMOVE SIDE GEAR SHAFT HOLDER
(a) Using snap ring pliers, remove the snap ring.
- TRANSFER (A540H)Component Parts (Transfer Right Case Retainer)TF-1 1
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AT4512
AT7778
AT3342
AT7780
SST
AT7779
(b) Using a plastic hammer, remove the side gear shaft
holder.
3. REMOVE HOLDER BEARING
(a) Using snap ring pliers, remove the snap ring.
(b) Using a press, press out the bearing.
4. REMOVE OIL SEAL
Using a screwdriver, remove the oil seal.
ASSEMBLY OF TRANSFER RIGHT CASE
RETAINER
1. INSTALL HOLDER BEARING
(a) Using SST and a press, press in the holder bearing.
SST 09226-10010
TF-12- TRANSFER (A540H)Component Parts (Transfer Right Case Retainer)
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AT4513
AT7781
AT3400
SST
AT3402
SST
AT7778
(b) Using snap ring pliers, install the snap ring.
2. INSTALL SIDE GEAR SHAFT HOLDER
(a) Install the side gear shaft holder.
(b) Using snap ring pliers, install the snap ring.
3. INSTALL OIL SEAL
(Left side oil seal)
(a) Coat a new oil seal lip with MP grease.
(b) Using a hammer and SST, drive in the oil seal.
SST 09316-60010 (09316-00010, 09316-00040)
Oil seal depth: 0 mm (0 in.)
(Right side oil seal)
(a) Coat a new oil seal lip with MP grease.
(b) Using a hammer and SST, drive in the oil seal.
SST 09608-32010, 09608-35014 (09608-06020)
Oil seal depth: 0 mm (0 in.)
- TRANSFER (A540H)Component Parts (Transfer Right Case Retainer)TF-13
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AT4514
AT4674
Stopper r Non-reusable part
AT4673
kg-cm (ft-lb, N-m) : Specified torque
55 (48 in.-lb, 5.4)
Strainer Oil Pump Driven GearTransfer Right Case Oil Pump Coverr O-Ring Oil Pump Driven Gear StopperOil Pump Driven Rotor
80 (69 in.-lb, 7.8)
Relief ValveCompression Springr O-Ring
250 (18, 25)
Oil Pump Drive Rotor
Transfer Right Case
COMPONENTS
DISASSEMBLY OF TRANSFER RIGHT CASE
1. INSPECT OIL PUMP OPERATION
Check that the oil pump turns smoothly with oil pump
driven gear.
2. REMOVE OIL PUMP DRIVEN GEAR STOPPER, OIL
PUMP COVER, DRIVE ROTOR AND DRIVEN ROTOR
(a) Remove the three bolts and oil pump driven gear
stopper.
(b) Pull out the oil pump cover, drive rotor and driven
rotor.
TF-14- TRANSFER (A540H)Component Parts (Transfer Right Case)
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AT4604
Matchmarks
AT4674
Stopper
AT4514AT4515
Relief Valve3. REMOVE RELIEF VALVE
Remove the relief valve and spring.
ASSEMBLY OF TRANSFER RIGHT CASE
1. INSTALL RELIEF VALVE
Install the relief valve and spring.
2. INSTALL OIL PUMP DRIVE ROTOR AND DRIVEN
ROTOR
Align the matchmarks on the drive rotor and the driven
rotor.
3. INSTALL OIL PUMP COVER AND DRIVEN GEAR
STOPPER
Torque the three bolts evenly.
Torque: 80 kg-cm (69 in.-lb, 7.8 N-m)
4. CHECK OPERATION OF OIL PUMP
Insert the oil pump driven gear to the drive rotor, check
that the drive rotor turns smoothly.
- TRANSFER (A540H)Component Parts (Transfer Right Case)TF-15
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AT4516
r Non-reusable part-cm (ft-lb, N-m)
: Specified torqueSide Gear Thrust WasherDifferential Side Left GearDifferential Pinion Shaft Holder Differential Pinion Thrust Washer Center Differential CaseSpacerRight GearWasherConical Spring 985 (71, 97)Oil Pump Drive GearShaft Snap
Ring r Left Case
BearingTransfer
Ring GearRing Gear Mounting
Left Caser O-RingRing Gear Mounting
Right Caser Right Case Bearing
Differential Pinion Thrust Washer
Differential Pinion Shaft Shaft Snap
RingDifferential Side
Ring Gear Mounting Case and
Center Differential Case
COMPONENTS
DISASSEMBLY OF RING GEAR MOUNTING
CASE AND CENTER DIFFERENTIAL CASE
1. REMOVE OIL PUMP DRIVE GEAR
(a) Using a screwdriver, remove the shaft snap ring.
TF-16- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)