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AT4419
SST
AT4493
SST
AT4494
AT4495AT4524
4. ADJUST TOTAL PRELOAD
(a) Install the transfer right case.
(b) Install and torque the ten bolts.
Torque: 450 kg-cm (33 ft-lb, 44 N-m)
HINT: Do not apply seal packing and do not install gasket.
Each bolt length (mm, in.) is indicated in the figure.
(c) Using SST and a spring tension gauge, measure
the total preload.
SST 09326-2001 1
Preload (at starting):
Add driven pinion preload
0.5 - 0.9 kg (1.1 - 2.0 lb, 4.9 - 8.8 N)
HINT: Turn the drive pinion counterclockwise and clock-
wise several times.
(d) Adjust the total preload by tightening the adjusting
nut with SST.
SST 09318-12010
HINT: Measure the preload while tightening the bearing
adjusting nut a little at a time.
5. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear back-
lash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
(b) When the backlash is outside the standard value,
select a different plate washer to the one selected in
step 3. Again adjust the backlash and total preload.
6. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at four different positions on the
ring gear with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
- TRANSFER (A540H)Assembly of Component PartsTF-33
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Mark ThicknessMark Thickness
A
B
C
D
E0.30 (0.0118)
0.33 (0.0130)
0.36 (0.0142)
0.39 (0.0154)
0.42 (0.0165)F
G
H
J
K0.45 (0.0177)
0.48 (0.0189)
0.51 (0.0201)
0.54 (0.0213)
0.57 (0.0224)
AT4310
Shim
AT4524
AT4492AT3397
Select an adjusting shim that will shift the
driven pinion away from the ring gear.Flank Contact Toe ContactSelect an adjusting shim that will bring the
driven pinion closer to the ring gear. Proper ContactFace Contact Heel Contact
Shim thicknessmm (in.)
(c) If the teeth are not connecting properly, again the
proper shim and plate washer.
7. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and transfer right case.
8. REMOVE RING GEAR MOUNTING CASE AND CENTER
DIFFERENTIAL CASE
TF-34- TRANSFER (A540H)Assembly of Component Parts
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AT4510
AT4616
AT4521
AT4522
SST
AT4491
9. REMOVE DRIVEN PINION BEARING CAGE
ASSEMBLY
Remove the six bolts and driven pinion bearing cage
assembly.
10. REMOVE DIFFERENTIAL LEFT SIDE BEARING
OUTER RACE AND PLATE WASHER
Using SST, remove the outer race and plate washer.
SST 09308-00010
11. INSTALL OIL SEAL
(a) Using SST, install a new oil seal as shown.
SST 09316-60010 (09316-00010, 09316-00030)
Oil seal depth: 3 mm (0.12 in.)
(b) Coat the lip of oil seal with MP grease.
12. INSTALL LEFT CASE BEARING OUTER RACE
(a) Install the plate washer. (previously selected)
(b) Using SST and a press, press in the outer race.
SST 09316-60010 (09316-00010, 09316-00060)
- TRANSFER (A540H)Assembly of Component PartsTF-35
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AT4507
Strainer Drive Gear
AT4492
AT4496
Gasket
AT4526 AT4491
13. INSTALL DRIVEN PINION BEARING CAGE ASSEMBLY
(a) Coat the O-ring with gear oil, and install it to the
bearing cage assembly.
(b) Install the bearing cage with adjust shim (Previously
selected) to the transfer left case.
(c) Install and torque the six bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
14. INSTALL RING GEAR MOUNTING CASE AND CENTER
DIFFERENTIAL CASE
15. INSTALL TRANSFER RIGHT CASE
(a) Install a new apply gasket to the left case.
(b) Coat the O-ring with gear oil.
(c) Install the O-ring to the oil pump strainer.
(d) Install the oil pump strainer to the transfer right
case.
(e) Install and torque the bolt.
Torque: 55 kg-cm (48 in.-lb, 5.4 N-m)
(f) Install the oil pump driven gear.
(g) Remove any packing material and be careful not
to drop oil on the contacting surfaces of the trans-
fer left case or right case.
(h) Apply seal packing to the left case as shown in the
figure.
Seal packing: Part No. 08826 - 00090 THREE BOND
1281 or equivalent
HINT: Install the right case as soon as the seal packing
is applied.
TF-36- TRANSFER (A540H)Assembly of Component Parts
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AT4508
Lock Plate
AT4525
AT4308
AT4418
O-Ring Gasket
AT4524
(i) Install the right case to the left case.
(j) Install and torque the ten bolts.
Torque: 450 kg-cm (33 ft-lb, 44 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
16. CHECK TOTAL PRELOAD
(See page AT-126)
17. INSTALL ADJUSTING NUT LOCK PLATE
(a) Install the lock plate so that the projection from
the lock plate fits properly into the groove of the
adjusting nut.
HINT: When the lock plate cannot be installed, tighten
the adjusting nut the smallest amount possible.
(b) Coat a new O-ring with gear oil and install it to
the lock bolt.
(c) Install and torque the lock bolt.
Torque: 73 kg-cm (63 in.-lb, 7 N-m)
18. INSTALL TRANSFER INSPECTION HOLE COVER
(a) Apply seal packing to the left case as shown in the
figure.
Seal packing: Part No. 08826-00090 THREE BOND
1281 or equivalent
HINT: Install the cover as soon as the seal packing is
applied.
(b) Install the hole cover to the transfer left case.
(c) Install and torque the three bolts.
Torque: 160 kg-cm (12 ft-lb. 16 N-m)
19. INSTALL TRANSFER RIGHT CASE RETAINER
(a) Coat a new O-ring with gear oil, and install it and
new apply gasket.
- TRANSFER (A540H)Assembly of Component PartsTF-37
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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
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AT4371BoltLever
AT4309
Torque:55 kg-cm (48 in.-lb, 5.4 N-m)
115 kg-cm (8 ft-lb, 11 N-m) 23. INSTALL TRANSFER MODE SELECT LEVER AND ROD
(a) Install the lever, rod and lever guide.
(b) Install and torque the two bolts.
(c) Install the bolt while setting the lever as shown.
Torque: 115 kg-cm (8 ft-lb, 11 N-m)
- TRANSFER (A540H)Assembly of Component PartsTF-39
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AIR CONDITIONING SYSTEM
± AIR CONDITIONING SYSTEMAC±1