Page 625 of 2389
HINT: During reassembly please refer to the spring specifications above to help discriminate be-
tween the different springs.
SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS
AND RETAINERS
(Transfer Lower Valve Body)
COMPONENTS
Transfer clutch modulator valveTransfer clutch modulator valveCoil outer diameter
mm (in.)
No. 2 Low±high shift valveNo. 2 Low±high shift valve
No. 1 Low±high shift valveNo. 1 Low±high shift valveFree length
mm (in.)Total No. of Coils
Thickness
mm (in.) Height mm
(in.)Width
mm (in.) RetainerSpring
Color
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±369
Page 626 of 2389

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 tower valve body into place.
(b1 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±Ib, 25 N±m)
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 ham
mer, drive in the oil seal as shown. 2. INSTALL SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
± AUTOMATIC TRANSAXLEComponent Parts(Transfer Transfer Lower Valve Body
A540H)AT±370
Page 627 of 2389
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 transfer shift lever.
HINT: Engage shift fork and transfer shift le-
ver.
(d) Install and tighten the lock bolts.
Torque: 40 kg±cm (35 in.±Ib, 3.9 N±m)
(b) Install the new transfer valve body gasket.
(e) Install the transfer valve body assembly.
(d) Tighten the bolts.
Torque: 110 kg±cm (8 ft±lb, 11 N±m)
4. INSTALL TRANSFER VALVE BODY ASSEMBLY
(a) Install the new transfer case gaskets and valve body
strainer.
(c) Install the solenoids.
.
Torque: 145 kg±cm (10 ft±Ib, 14 N±m)
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±371
Page 628 of 2389
ASSEMBLY OF COMPONENT PARTS
1. INSTALL CASE SIDE
(a) Install the plate washer.
HINT: First install a washer of the same thickness as
before.
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 be-
fore 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 reservoir, un-
til it touches the outer race. (b) Using SST and a press, press in the outer race.
SST 09316±60010 (09316±00010, 09316±00060)
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±372
Page 629 of 2389
(c) Install the ring gear mounting case and center differential
case.
(d) Using a dial indicator, measure the ring gear backlash.
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 specification. Try to select a washer of
the same size.
Plate washer thickness mm (in)(b) Install the driven pinion bearing cage.
Torque: 400 kg±cm (29 ft±Ib, 39 N±m)
HINT: Do not install the O±ring.
Thickness
Thickness Mark
Mark
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±373
Page 630 of 2389

4. ADJUST TOTAL PRELOAD
(a) Install the transfer right case.
(b) Install and torque the ten bolts.
Torque: 450 kg±cm (33 ft±Ib, 44 N±m)
HINT: Do not apply seal packing and do not install gas-
ket. Each bolt length (mm (in.) is indicated in the figure.
(c) Using SST and a spring tension gauge, mea-
sure the total preload.
SST 09326±20011
Preload (at starting):
Add driven pinion preload
0.5±0.9kg (1.1 ±2.0lb,4.9±8.8N)
HINT: Turn the drive pinion counterclockwise and
clockwise several times.
5. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear backlash.
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. (d) Adjust the total preload by tightening the adjust-
ing nut with SST.
SST 09318±12010
HINT: Measure the preload while tightening the
bearing adjusting nut a little at a time.
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.
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
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Page 631 of 2389
(e) If the teeth are not connecting properly, again the
proper shim and plate washer.
8. REMOVE RING GEAR MOUNTING CASE AND CENTER
DIFFERENTIAL CASE 7. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and transfer right case.
Thickness
Thickness
mm (in.)
Mark
Mark
Shim thickness
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±375
Page 632 of 2389
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. 10. REMOVE DIFFERENTIAL LEFT SIDE BEARING OUTER
RACE AND PLATE WASHER
Using SST, remove the outer race and plate washer.
SST 09308±00010 9. REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY
Remove the six bolts and driven pinion bearing cage assembly.
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)
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±376