Page 641 of 2389
8. Be sure to install. the thrust bearings and races in the correct direction and position.
Bearing
(with race)
Front
Bearing
Race
Rear
Bearing
RaceInner
Diameter
Inner
DiameterInner
Diameter
Inner
DiameterOuter
Diameter
Outer
Diameter
Outer
Diameter
Outer
Diameter Thrust
BearingA540HA540E
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±383
Page 642 of 2389
INSTALLATION OF DIFFERENTIAL AND
DRIVE. PINION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
(a) Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with
the pinion shaft. (A540E)
(b) Install the two new O±rings to the bearing cage.
(A540E)
(c) Coat the O±rings with ATF. (A540E)
(d) Using a hammer and brass bar, slightly tap the
bearing cage into the transaxle case until the
snap ring groove in the bore can be seen.
(e) Using SST, install snap ring into the bore.
SST 09350±32014 (09351±32050`
2. (A540E)
PLACE SENSOR ROTOR ONTO DRIVE PINION
SHAFT
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±384
Page 643 of 2389
6. INSTALL COUNTER DRIVEN GEAR
(a) Place SST into the transaxle hole to hold the drive pinion
shaft.
SST (a) 09350±32014 (09351±32130, 09351±32150)
(b) Using SST, press in the counter driven gear until slightly
thickness between the counter driven gear bearing and
outer race.
SST (b) 09350±32014 (09351±32140)
7. INSTALL NEW LOCK NUT AND ADJUST DRIVE
PINION PRELOAD
(a) Install the new lock nut.
(b) Using SST to hold the gear, tighten the nut.
Torque: 2,100 kg±cm (152 ft±Ib, 206 N±m)
SST 09330±00021, 09350±32014 (09351±32032) 5. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350±32014 (09351±32100, 09351±32140) 4. PLACE OIL SLINGER AND NEW SPACER
HINT: Install the spacer with the small end downward. 3.(A540H)
INSTALL DRIVE PINION BEARING NO. 2 SPACER
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±385
Page 644 of 2389

Turn the gear counterclockwise and clockwise several
times.
(d) Using a torque meter, measure the preload of the drive
pinion.
Drive pinion preload (at starting):
New bearing
10 ± 16 kg±cm
(8.7 ± 13.9 in.±Ib, 1.0 ± 1.6 N±m)
Reused bearing
5 ± 8 kg±cm
(4.3 ± 6.9 in.±Ib, 0.5 ± 0.8 N±m)
wIf the preload is greater than specified, replace the
bearing spacer.
wIf the preload is less than specified, retighten the nut
130 kg±cm (9 ft±Ib, 13 N±m) at a time until the specified
preload is reached.
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 3,640 kg±cm (260ft±Ib, 353 N±m)
(e) If the preload is adjusted within specification, make a
note of it.
M Stake the lock nut.
9. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE
(A540E) Be sure to install the shim and outer rece into
place. 8. (AS40E)
PLACE OUTER RACE AND SHIM ONTO RH SIDE
BEARING
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±386
Page 645 of 2389
10. INSTALL CARRIER COVER
(a) Remove any packing material and be careful not to drop oil on
the contacting surfaces of the carrier cover and transaxle
case.
(b) Apply seat packing to the carrier cover as shown.
Seal packing: Part No. 08826±00090, THREE BOND
1281 or equivalent
HINT: Install the carrier cover within ten minutes after applying
seal packing.
(d) Install and torque the eleven bolts.
Torque: 400 kg±cm (29 ft±lb, 39 N±m)
HINT: Each bolt length (mm (in)) is indicated in the
figure. (A540H)
Be sure to install the ring gear mount case sleeve
and outer race into place.
(e) Install the two apply gaskets.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±387
Page 646 of 2389
11. ADJUST SIDE BEARING PRELOAD
1ay Remove any packing material on the contacting
surfaces of the LH bearing retainer and transaxle case.
HINT: Do not apply seal packing yet.
W Install the LH bearing retainer and torque the six
bolts.
Torque: 195 kg±cm (14 ft±lb, 19 N±m)
Snap down the bearings by turning the differential case
several times.
(d) Using a torque meter, measure the differential total
preload.
Total preload (at starting):
Add drive pinion preload
If the preload is not within specification, replace tho adjust-
ing shim in the LH bearing retainer with another thickness
one.
kg±cm (in±Ib, N±m)
Reused Bearing
New Bearing
Thickness
Thickness A540H A540E
Mark
Markmm (in)
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±388
Page 647 of 2389
(b) Remove any packing material on the contacting surfaces of
LH bearing retainer, transaxle case and carrier cover.
(c) Apply the seal packing to the transaxle case and carrier cover
as shown.
Seal packing: Part No. 08826±00090, THREE BOND
1281 or equivalent
HINT: Install the LH bearing retainer with ten minutes after ap-
plying seal packing.
(d) Install the LH bearing retainer.
(e) Coat the threads of bolts with sealer.
Sealer: Part No. 08833±00070, THREE BOND 1324
or equivalent
(f) Tighten the bolts.
Torque: 195 kg±cm (14 ft±Ib, 19 N±m)
(g) Snap down the bearings.
(h) Recheck the differential total preload.
(b) Using SST, driven in a new oil seal until its end is flush with the
surface of the LH bearing retainer.
SST 09223±15010 13. INSTALL NEW OIL SEAL
(a) Place the oil baffle onto the LH bearing retainer. 12. INSTALL LH BEARING RETAINER
(a) Remove the six bolts and LH bearing retainer.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±389
Page 648 of 2389
14. (A540E)
INSTALL RH RETAINER
(a) Remove any packing material on the contacting surfaces of
RH retainer and transaxle case.
(b) Apply the seal packing to the RH retainer as shown.
Seal packing: Part No. 08826±00090, THREE BOND
1281 or equivalent
HINT: Install the RH retainer within ten minutes after applying
seal packing.
(e) Coat the threads of bolts with sealer.
Sealer: Part No. 08833±00070, THREE BOND 1324
or equivalent
(d) Tighten the bolts.
Torque: 196 kg±cm 114 ft±Ib, 19 N±m)
15. INSTALL DRIVE PINION CAP
(a) Install a new O±ring to the cap.
(b) Install the drive pinion cap to the transaxle case.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±390