Page 185 of 2389
AT4605
r Non-reusable part
Precoated part: Specified torque
kg-cm (ft-lb, N-m)Differential Lock
Shift Fork ShaftTransfer Left Case Differential Lock
Shift Forkr Oil Seal Ball Spring
120 (9, 12)
Head PlugTransfer Shift Lever Valve Body StrainerDifferential Lock Sleeve Transfer Valve Body
Gasket r Transfer Case GasketTransfer Valve Body Assemblyr O-ring
110 (8, 11)Center Differential Control Solenoidr O-ring
70 (61 in.-lb, 6.9) 145 (10, 14)
Transfer Left Case
COMPONENTS
- TRANSFER (A540H)Component Parts (Transfer Left Case)TF-25
Page 186 of 2389
AT4520
O-ringO-ring
AT4606
AT4607
GasketStrainer
AT4608
Shift Lever
AT4519
DISASSEMBLY OF TRANSFER LEFT CASE
1. REMOVE CENTER DIFFERENTIAL CONTROL
SOLENOIDS
(a) Remove the four bolts and solenoid.
(b) Remove the four O-rings from the solenoids.
2. REMOVE TRANSFER VALVE BODY ASSEMBLY
(a) Remove the eight bolts and transfer valve body
assembly.
(b) Remove the transfer valve body gasket.
(c) Remove transfer case gaskets and valve body
strainer.
3. REMOVE TRANSFER SHIFT LEVER
(a) Remove the lock bolt and transfer shift lever.
TF-26- TRANSFER (A540H)Component Parts (Transfer Left Case)
Page 187 of 2389
AT4609
AT4610
AT4612
AT4613
GasketPlate
AT4611
Shift Fork Shaft Shift ForkHead Plug
(b) Using a screwdriver, remove the oil seal.
4. REMOVE SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
5. REMOVE SHIFT FORK SHAFT FROM SHIFT FORK
(a) Remove the head plug, spring and ball.
(b) Pull out the shift fork shaft from shift fork.
DISASSEMBLY OF TRANSFER VALVE BODY
REMOVE TRANSFER LOWER VALVE BODY
(a) Remove the eight bolts and transfer lower valve
body.
(b) Remove the two gaskets and plate from the
transfer upper valve body.
- TRANSFER (A540H)Component Parts (Transfer Left Case)TF-27
Page 188 of 2389
SpringFree length
mm (in.)Coil outer diameter
mm (in.)Total No. of Coils
Color
Transfer clutch modulator valve 32.3 (1.272) 7.6 (0.299) 16None
No. 2 Low-high shift valve
28.9 (1.138) 7.0 (0.276) 14None
No. 1 Low-high shift valve
RetainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
6.5
(0.256)5.0
(0.197)3.2
(0.126) No. 2 Low-high shift valve
No. 1 Low-high shift valve
AT4425
PlugRetainerNo. 1 Low-High
Shift ValveLower Valve Body Transfer Clutch
Modulator ValveNo. 2 Low-High
Shift Valve
Transfer Lower Valve Body
COMPONENTS
SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS AND RETAINERS
HINT: During reassembly please refer to the spring specifications above to help discriminate between the
different springs.
TF-28- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)
Page 189 of 2389

AT4612
AT4964
Shift Fork ShaftShift Fork
AT4610
AT4614 AT4613
GasketPlate
ASSEMBLY OF TRANSFER VALVE BODY
1. INSTALL PLATE AND NEW GASKETS ON TRANSFER
LOWER VALVE BODY
Install a new gasket and plate and then the other new
gasket.
HINT: Both gaskets are the same.
2. INSTALL TRANSFER LOWER VALVE BODY
Each bolt length (mm, in.) is indicated in the figure.
(a) Lower the transfer lower valve body into place.
(b) Hand tighten the eight bolts first. Then, tighten
them with a torque wrench.
Torque: 67 kg-cm (58 in.-lb, 6.6 N-m)
ASSEMBLY OF TRANSFER LEFT CASE
1. INSTALL SHIFT FORK SHAFT TO SHIFT FORK
(a) Insert the shift fork shaft into the shift fork.
(b) Install the ball, spring and head plug.
(c) Tighten the plug.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
2. INSTALL SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
3. INSTALL TRANSFER SHIFT LEVER
(a) Coat the lip of new oil seal with MP grease.
(b) Using a 17 mm (0.67 in.) socket wrench and
hammer, drive in the oil seal as shown.
- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)TF-29
Page 190 of 2389
AT4607
Strainer
Gasket
AT4606
AT4520
O-ringO-ring
AT4519 AT4615
Lock BoltShift
Lever Shift
Fork
(c) Install transfer shift lever.
HINT: Engage shift fork and transfer shift lever.
(d) Install and tighten the lock bolts.
Torque: 40 kg-cm (35 in.-lb, 3.9 N-m)
4. INSTALL TRANSFER VALVE BODY ASSEMBLY
(a) Install the new transfer case gaskets and valve
body strainer.
(b) Install the new transfer valve body gasket.
(c) Install the transfer valve body assembly.
(d) Tighten the bolts.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
5. INSTALL CENTER DIFFERENTIAL CONTROL
SOLENOIDS
(a) Install the four new O-rings to the solenoids.
(b) Coat the O-rings with ATF.
(c) Install the solenoids.
Torque: 145 kg-cm (10 ft-lb, 14 N-m)
TF-30- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)
Page 191 of 2389
AT4521
AT4522
SST
AT4523
SST
AT4573
Oil Reserver Adjusting Nut
AT4310
Shim
ASSEMBLY OF COMPONENT PARTS
1. INSTALL CASE SIDE
(a) Install the plate washer.
HINT: First install a washer of the same thickness as
before.
(b) Using SST and a press, press in the outer race.
SST 09316-60010 (09316-00010, 09316-00060)
2. INSTALL RIGHT CASE SIDE
(a) Using SST and a press, press in outer race as
shown.
SST 09316-60010 (09316-00010, 09316-00060)
(b) Install the bearing adjusting nut and oil reserver,
until it touches the outer race.
3. ADJUST RING GEAR BACKLASH
(a) Install the two shims to the driven pinion bearing
cage assembly.
HINT: First install shims of the same thickness as
before.
- TRANSFER (A540H)Assembly of Component PartsTF-31
Page 192 of 2389
AT4491
AT4492
Mark Thickness
Mark Thickness
712.13 (0.0839)
832.49 (0.0980)
72 2.16 (0.0850)
842.52 (0.0992)
732.19 (0.0862)
852.55 (0.1004)
742.22 (0.0874)
862.58 (0.1016)
752.25 (0.0886)
872.61 (0.1028)
762.28 (0.0898)
882.64 (0.1039)
772.31 (0.0909)
892.67 (0.1051)
782.34 (0.0921)
902.70 (0.1063)
792.37 (0.0933)
912.73 (0.1075)
802.40 (0.0945)
922.76 (0.1087)
812.43 (0.0957)
932.79 (0.1098)
822.46 (0.0969)
942.82 (0.1110)
AT3364
AT4521
Plate washer thicknessmm (in.)
(b) Install the driven pinion bearing cage.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
HINT: Do not install the O-ring.
(c) Install the ring gear mounting case and center
differential case.
(d) Using a dial indicator, measure the ring gear back-
lash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
(e) Referring to the table below, select the plate washer
which will ensure that the backlash is within specifi-
cation. Try to select a washer of the same size.
TF-32- TRANSFER (A540H)Assembly of Component Parts