Page 617 of 2389
(c) Using a dial indicator, measure the backlash of one pinion
gear while holding the side gear toward the case.
Standard backlash: 0.05 ± 0.20 mm (0.002 ± 0.0079 in.)
HINT: Do not place in a vise the surface of the center dif-
ferential case which comes in contact with the bushing.
Referring to the table below, select the thrust washer
which will ensure that the backlash is within specification.
Try to select a washer of the same size.
5. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE
(a) Install the differential side right gear.
HINT: Do not install the conical spring washer.(d) Using snap ring pliers, install the shaft snap ring.
(b) Install the center differential case.
Thickness mm (in.)
Thickness mm (in.) MarkMark
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Ring Gear Mounting Case
and Center Differential Case A540H)AT±362
Page 618 of 2389
(d) Align the matchmarks on the ring gear mounting
left and right case.
(e) Install and torque the twelve bolts.
Torque: 985 kg±cm (71 ft±Ib, 97 N±m)
HINT: Do not install the O±ring.
(f) Using a caliper, measure the conical spring wash-
er thickness.
Using a dial indicator, measure the thrust clear-
ance of center differential case while holding
the ring gear mounting case.
Standard clearance:
(h) Referring to the table below, select the thrust washer
which will ensure that the backlash is within specifica-
tion. Try to select a washer of the same size.(c) Install the thrust washer.
Thickness mm (in.)Thickness mm (in.)
MarkMark
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Ring Gear Mounting Case
and Center Differential Case A540H)AT±363
Page 619 of 2389
9. INSTALL RING GEAR MOUNTING LEFT CASE
(a) Coat the new O±ring with ATF, and install it onto the
left case.
(b) Align the matchmarks on the right and left case.
(c) Install and torque the twelve bolts.
Torque: 985 kg±cm (71 ft±Ib, 97 N±m)
NOTICE: Using the soft jaws, hold the left case in a vise.
6. INSTALL DIFFERENTIAL SIDE GEAR AND CONICAL
SPRING WASHER
HINT: Be careful not to make a mistake in the direction
of the conical spring washer.
10. INSTALL OIL PUMP DRIVE GEAR
(a) Install the oil pump drive gear. 7. INSTALL CENTER DIFFERENTIAL CASE
8. INSTALL THRUST WASHER (Previously selected)
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Ring Gear Mounting Case
and Center Differential Case A540H)AT±364
Page 620 of 2389
(b) Install the shaft snap ring.
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Ring Gear Mounting Case
and Center Differential Case A540H)AT±365
Page 621 of 2389
Torque Converter
INSPECTION OF TORQUE CONVERTER
1. INSERT SST IN END OF TORQUE CONVERTER
(a) Insert a turning tool into the inner race of the one±way
clutch.
SST 09350±32014 (09351±32010)
2. TEST ONE±WAY CLUTCH
With the torque converter made stand, the clutch
should lock when turned counterclockwise, and rotate
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.
CLEAN TORQUE CONVERTER
if the transmission is contaminated, the torque convert-
er and transmission cooler should be thoroughly
flushed with ATF. (b) Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one±way
clutch.
SST 09350±32014 (09351±32020)
± AUTOMATIC TRANSAXLEComponent Parts (Torque Converter) (A540E and
A540H)AT±381
Page 622 of 2389
(Transfer Left Case)
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Left Case A540H)AT±366
Page 623 of 2389
2. REMOVE TRANSFER VALVE BODY ASSEMBLY
(a) Remove the eight bolts and transfer valve body as-
sembly.
(b) Remove the transfer valve body gasket.
DISASSEMBLY OF TRANSFER LEFT CASE
1. REMOVE CENTER DIFFERENTIAL CONTROL
SOLENOIDS
(a) Remove the four bolts and solenoids.
3. REMOVE TRANSFER SHIFT LEVER
(a) Remove the lock bolt and transfer shift lever.(c) Remove transfer case gaskets and valve body
strainer. (b) Remove the four O±rings from the solenoids.
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Left Case A540H)AT±367
Page 624 of 2389
DISASSEMBLY OF TRANSFER VALVE
BODY
REMOVE TRANSFER LOWER VALVE BODY
(a) Remove the eight bolts and transfer lower valve(
body. 5. REMOVE SHIFT FORK SHAFT FROM SHIFT FORK
(a) Remove the head plug, spring and bail.
(b) Pull out the shift fork shaft from shift fork.
(b) Remove the two gaskets and plate from the
transfer upper valve body. 4. REMOVE SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE(b) Using a screwdriver, remove the oil seal.
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Left Case A540H)AT±368