Toyota 1991 Camry Repair Manual
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Toyota 1991 Camry Repair Manual

Toyota 1991 Camry Repair Manual

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FOREWORD
This repair manual covers Disassembly, Inspection and As-
sembly procedures for the following Automatic Transaxles:
Automatic Transmission
A540E
A540H
For On-vehicle Servicing (Inspection, Adjustment, Trouble-
shooting, Removal and Installation) of Automatic Transaxle,
refer to the repair manual for the applicable vehicle model.
Pub. Name
'91 Camry Repair Manual
All information contained in this manual is the most up-to-data
at the time of publication. However, specifications and proce-
dures are subject to change without notice.
Applicable Model
'91 Camry
TOYOTA MOTOR CORPORATION
Pub. No.
RM199U

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Summary of Contents for Toyota 1991 Camry

  • Page 1 Pub. No. Pub. Name RM199U ’91 Camry Repair Manual All information contained in this manual is the most up-to-data at the time of publication. However, specifications and proce- dures are subject to change without notice. TOYOTA MOTOR CORPORATION...

  • Page 2: How To Use This Manual

    IN-2 INTRODUCTION How to Use This Manual HOW TO USE THIS MANUAL To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. An INDEX is provided on the 1st page of each section to guide you to the item to be repaired.

  • Page 3: Specifications

    IN-3 INTRODUCTION How to Use This Manual The procedures are presented in a step-by-step format: Illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.

  • Page 4: General Repair Instructions

    IN-4 INTRODUCTION General Repair Instructions GENERAL REPAIR INSTRUCTIONS Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in order to facilitate reassembly. Observe the following: Before performing electrical work, disconnect the negative cable four the battery terminal.
  • Page 5 IN-5 INTRODUCTION General Repair Instructions When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tighten- ing torques. Always use a torque wrench. Use of special service tools (SST) and special ser- vice materials (SSM) may be required, depending on the nature of the repair.
  • Page 6 IN-6 INTRODUCTION Abbreviations Used in This Manual ABBREVIATIONS USED IN THIS MANUAL A/T ATM Automatic Transmission Automatic Transmission Fluid Overdrive Brake Second Coast Brake Second Brake First and Reverse Brake Overdrive Clutch Forward Clutch Direct Clutch Disc Differential Left Multipurpose Overdrive Plate Right...
  • Page 7 Adjusting Nut Wrench A540H Transmission Oil 09325 - 12010 Plug A540H Transmission Oil 09325 - 20010 Plug A540H Output Shaft Bearing 09326 - 20011 Lock Nut Wrench A540H Companion Flange 09330 - 00021 Holding Tool TOYOTA Automatic Transmission Tool 09350 - 32014...
  • Page 8 AT-10 AUTOMATIC TRANSAXLE Preparation SST (SPECIAL SERVICE TOOLS) (Cont’d) Illustration Part No. Part Name Note (09308 - 10010) (Oil Seal Puller) Counter Driven Gear (09351 - 32032) Holding Tool No. 1 Piston Spring (09351 - 32040) Compressor (09351 - 32050) (Snap Ring Expander) (09351 - 32061) (Oil Pump Puller)
  • Page 9 AT-1 1 AUTOMATIC TRANSAXLE Preparation SST (SPECIAL SERVICE TOOLS) (Cont’d) Note Part Name Illustration Part No. A540H Differential Bearing 09502 - 12010 Replacer A540H Differential Drive Pinion Rear Bearing 09506 - 35010 Replacer A540H Differential Side Gear 09520 - 32012 Shaft Puller A540H Front Hub Bearing...
  • Page 10 AT-12 AUTOMATIC TRANSAXLE Preparation SSM (SPECIAL SERVICE MATERIALS) Part Name Part No. Use etc. Transfer right case Transfer left case (A540H) Transfer inspection hole cover (A540H) Seal packing 1281, Transfer case Differential carrier cover 08826 - 00090 Three bond 1281 or equivalent Differential LH bearing retainer (A540E, A540H) Differential RH retainer (A540E) Transaxle...
  • Page 11 STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH Class Class Mark Mark Stud bolt Hexagon head bolt Bolt head No. No mark No mark Hexagon flange bolt No mark Grooved w/ washer hexagon bolt Hexagon head bolt protruding lines...
  • Page 12 STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class Hexagon head bolt Hexagon flange bolt kg-cm ft-lb kg-cm ft-lb 52 in.-Ib 48 in.-Ib 1.25 12.5 1.25 1.25 1,150 56 in.-Ib 65 in.-lb 17.5 1.25 15.5 1.25 1.25 1,050...
  • Page 13 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) AUTOMATIC TRANSAXLE (A540E) Specifications Second Piston stroke 2.0 - 3.5 mm 0.079 - 0.138 in. coast brake Piston rod length 95.2 mm 3.748 in. 96.3 mm 3.791 in. Oil pump Body clearance 0.07 - 0.15 mm 0.0028 - 0.0059 in.
  • Page 14 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Specifications (Cont’d) Valve body Coil outer Total Free length spring Spring diameter No. of Color mm (in.) mm (in.) coils (Upper valve body) Second coast modulator valve 27.5 (1.083) 8.9 (0.350) 14.6 Brown orifice control valve 24.8 (0.976) 8.0 (0.315)
  • Page 15 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Specifications (Cont’d) Accumulator Coil outer Total Free length spring diameter Spring No. of Color mm (in.) mm (in.) coils 43.4 (1.709) Inner 17.8 (0.701) Light Green Outer 71.2 (2.803) 24.4 (0.961) 11.5 Blue 51.0 (2.008) 18.0 (0.709) 10.2...

  • Page 16: Torque Specifications

    SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Torque Specifications ft-lb Part tightened kg-cm Oil cooler pipe union 43 in.-lb Oil pan Valve body Transaxle case Accumulator Cover Oil pump Transaxle case O/D case Transaxle case Differential LH side bearing retainer Differential RH retainer Differential carrier cover Oil pump body...
  • Page 17 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Specifications (Cont’d) Drive pinion preload (at staring) Differential New bearing 10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m Reused bearing 5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m Total preload (at starting) New bearing 2.3 - 3.7 kg-cm...
  • Page 18 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Specifications (Cont’d) Center differential left side gear Mark Transfer 1.00 mm 0.0394 in. thrust washer thickness (Cont’d) 1.05 mm 0.0413 in. 1.10 mm 0.0433 in. 1.15 mm 0.0453 in. 1.20 mm 0.0472 in. 1.25 mm 0.0492 in.
  • Page 19 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Specifications (Cont’d) Transfer 2.43 mm 0.0957 in. (Cont’d) 2.46 mm 0.0969 in. 2.49 mm 0.0980 in. 2.52 mm 0.0992 in. 2.55 mm 0.1004 in. 2.58 mm 0.1016 in. 2.61 mm 0.1028 in. 2.64 mm 0.1039 in.
  • Page 20 SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) Torque Specifications (Cont’d) Part tightened kg-cm ft-lb 48 in.-lb Transfer right case Oil strainer 48 in.-lb Transfer left case Rear wheel speed sensor Transfer left case Transfer inspection hole cover Transfer left case Drain plug Transfer left case Driven pinion bearing cage...
  • Page 21 AT-2 AUTOMATIC TRANSAXLE Description DESCRIPTION GENERAL (A540E) The A540E is a 4-speed, Electronic Controlled Transaxle (hereafter called ECT) developed exclusively for use with a transversely-mounted engine. A lock-up is built into the torque converter. The A540E transaxle is mainly composed of the torque converter, the 4-speed planetary gear unit, the differential, the hydraulic control system and the electronic control system.
  • Page 22 AT-3 AUTOMATIC TRANSAXLE Description (A540H) The A540H automatic transaxle design is based on the A540E automatic transaxle and equipped with a center differential and transfer. This transaxle has the same hydraulic multiplate clutch in the center differential limiting control mecha- nism as the A241H automatic transaxle on the Corolla All-Trac/4WD Station Wagon.

  • Page 23: General Specification

    AT-4 AUTOMATIC TRANSAXLE Description General Specification Type of Transmission A540E A540H Type of Engine 2VZ-FE 3S-FE Stall Torque Ratio 1.9 : 1 2.0 : 1 Torque Converter Lock-Up Mechanism Equipped 1st Gear 2.810 2nd Gear 1.549 Gear Ratio 3rd Gear 1.000 O/D Gear 0.734...
  • Page 24 AT-5 AUTOMATIC TRANSAXLE Operation OPERATION Planetary Gear Unit Second Coast First and Reverse Brake (B O/D Direct Second Brake (B Brake (B Clutch (C One-W ay Clutch Direct Forward O/D Brake (B No. 2 (F Clutch (C Clutch (C Counter One-W ay Clutch O/D One-Way Input Shaft...
  • Page 25 AT-6 AUTOMATIC TRANSAXLE Operation FUNCTION OF COMPONENTS NOMENCLATURE OPERATION Forward Clutch Connects input shaft and front planetary ring gear Direct Clutch Connects input shaft and front & rear planetary sun gear 2nd Coast Brake Prevents front & rear planetary sun gear from turning either clockwise or counterclockwise Prevents outer race of F from turning either clockwise or counterclockwise, thus preventing front &...
  • Page 26 AT-7 AUTOMATIC TRANSAXLE Operation Power from the engine transmitted to the input shaft via the torque converter is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one-way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit.
  • Page 27 AT-8 AUTOMATIC TRANSAXLE Operation Hydraulic Control System R A540E, A540H The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accu- mulators, the clutches and brakes, and the governor valve as well as the fluid passages which connect all of these components.

  • Page 28: Component Parts

    AT-39 AUTOMATIC TRANSAXLE Component Parts (General Notes) COMPONENT PARTS General Notes The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time.
  • Page 29 AT-40 AUTOMATIC TRANSAXLE Component Parts (Second Coast Brake) Second Coast Brake COMPONENTS Outer Spring Piston Rod Plate Washer Second Coast Inner Spring Brake Band Oil Seal Ring Piston O-Ring E-Ring Cover Snap Ring Non-reusable part AT3606 DISASSEMBLY OF SECOND COAST BRAKE PISTON REMOVE OIL SEAL RING Remove the oil seal ring from the piston.
  • Page 30 AT-41 AUTOMATIC TRANSAXLE Component Parts (Second Coast Brake) Remove the inner spring, plate washer and piston Plate Washer Inner Spring rod. Piston Rod AT7704 INSPECTION OF SECOND COAST BRAKE COMPONENT If the lining of the brake band is exfoliated or discolored, or even part of the printed marks is defaced, replace the Printed Mark brake band.
  • Page 31 AT-42 AUTOMATIC TRANSAXLE Component Parts (Second Coast Brake) INSTALL OIL SEAL RING Less than 5 mm (0.20 in.) Apply ATF to the oil seal ring. Install the oil seal ring to the piston. NOTICE: Do not spread the ring ends more than necessary.
  • Page 32 AT-13 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVAL OF COMPONENT PARTS COMPONENTS A540E and A540H Breather Tube (A540H) Solenoid Wire O-Ring 200 (14, 20) Breather Hose 100 (7, 10) (A540H) Transaxle Case Union (A540H) Upper Cover 275 (20, 27) Gasket Transaxle Case O-Ring Upper Cover (A540H)
  • Page 33 AT-14 AUTOMATIC TRANSAXLE Removal of Component Parts COMPONENTS (Cont’d) A540E and A540H Manual Valve Lever Collar Manual Valve Shaft Retaining Spring Oil Seal Spring Parking Lock Rod Valve Body Second Brake O-Ring Apply Gasket Accumulator Spring Piston O-Ring O-Ring Spring Apply Tube Detent Spring Accumulator...
  • Page 34 AT-15 AUTOMATIC TRANSAXLE Removal of Component Parts COMPONENTS (Cont’d) A540E and A540H Forward Clutch Front Planetary Thrust Washer No. 1 One-way Ring Gear Clutch Direct Clutch Front Planetary O-Ring Second Coast Gear Thrust Brake Band Washer Oil Pump Thrust Thrust Washer Bearing Washer...
  • Page 35 AT-16 AUTOMATIC TRANSAXLE Removal of Component Parts COMPONENTS (Cont’d) A540E Drive Pinion Cap O-Ring 195 (14, 19) Bearing Drive Case Pinion RH Retainer Carrier Cover Gasket O-Ring Snap Ring Sensor Rotor Filler Plug Counter Driven Gear Drain Plug Spacer Gasket 400 (29, 39) Oil Slinger Outer Race...
  • Page 36 AT-17 AUTOMATIC TRANSAXLE Removal of Component Parts COMPONENTS (Cont’d) A540H Drive Pinion Cap Apply Gasket O-Ring Transfer Assembly Vehicle Bearing Speed Sensor Cage O-Ring Plug O-Ring Carrier Cover Drive Pinion Apply Gasket Snap Ring Plug O-Ring O-Ring Drive Pinion No. 2 Spacer Gasket Spacer Drain Plug...
  • Page 37 AT-18 AUTOMATIC TRANSAXLE Removal of Component Parts SEPARATE BASIC SUBASSEMBLY A540H (A540H) REMOVE TRANSFER ASSEMBLY Remove the five nuts and three bolts. Using a plastic hammer, remove the transfer as- sembly form the transaxle. AT4600 (A540H) A540H REMOVE APPLY GASKET Apply Gasket AT4221...
  • Page 38 AT-19 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE REMOVE SOLENOID WIRE RETAINING BOLT AT3529 (A540E) A540E REMOVE NO. 2 SPEED SENSOR Disconnect the connector. Remove the bolt and pull out the speed sensor. Remove the O-ring from speed sensor. AT3530 (A540H) A540H...
  • Page 39 AT-20 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE OIL TUBE BRACKET AND STRAINER Oil Tube Bracket Strainer AT3532 REMOVE MANUAL VALVE BODY Remove the two bolts and detent spring. AT5049 Remove the five bolts and manual valve body with the manual valve. Remove the manual valve from the manual valve body.
  • Page 40 AT-21 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE CONNECTOR CLAMP AND TUBE RETAINER Clamp Retainer AT3534 REMOVE B APPLY TUBE Pry up the tube with a screwdriver and remove the tube. AT3535 REMOVE VALVE BODY Remove the ten bolts. AT4178 Disconnect the throttle cable from the cam and remove the valve body.
  • Page 41 AT-22 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE THROTTLE CABLE AND SOLENOID WIRE AT3538 REMOVE ACCUMULATOR PISTONS AND SPRINGS Loosen the five bolts one turn at a time until the spring tension is released. Remove the cover and gasket. AT3539 Remove the C accumulator piston.
  • Page 42 AT-23 AUTOMATIC TRANSAXLE Removal of Component Parts Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/cm 57 - 114 psi or 392 - 785 kPa) as shown. 09240-00020 Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 in.) If the piston stroke exceeds the limit, inspect the second coast brake band (See page AT-41).
  • Page 43 AT-24 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE O-RING FROM OIL PUMP AT7700 REMOVE DIRECT CLUTCH AND FORWARD CLUTCH AT3547 SEPARATE DIRECT CLUTCH AND FORWARD Direct Clutch CLUTCH Thrust Washer Separate the direct clutch and forward clutch. Remove the thrust washer from direct clutch. Forward Clutch AT3548 REMOVE BEARINGS FROM FORWARD CLUTCH...
  • Page 44 AT-25 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE FRONT PLANETARY RING GEAR AT3550 REMOVE FRONT PLANETARY GEAR Remove the front planetary gear. AT3551 Remove the two bearings from the planetary gear AT3600 REMOVE SUN GEAR AND SUN GEAR INPUT DRUM Remove the sun gear and sun gear input drum.
  • Page 45 AT-26 AUTOMATIC TRANSAXLE Removal of Component Parts CHECK OPERATION OF SECOND BRAKE PISTON Apply compressed air into the case passage and con- firm that the piston moves. If the piston does not move, disassemble and inspect. AT3601 REMOVE SECOND COAST BRAKE BAND GUIDE AT3554 REMOVE SECOND BRAKE DRUM Remove the snap ring.
  • Page 46 AT-27 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE NO. 1 ONE-WAY CLUTCH AT3557 REMOVE PLATES, DISCS AND FLANGE HINT: For the method of inspection, refer to page AT-62. AT3558 REMOVE SECOND BRAKE DRUM GASKET Remove the gasket. AT7701 REMOVE NO. 2 ONE-WAY CLUTCH AND REAR PLANETARY GEAR Remove the snap ring.
  • Page 47 AT-28 AUTOMATIC TRANSAXLE Removal of Component Parts Remove the thrust washer from the rear planetary gear. A540H only AT5021 REMOVE REAR PLANETARY RING GEAR Bearing Remove the rear planetary ring gear. Remove the bearing from the ring gear. AT3562 CHECK FIRST AND REVERSE BRAKE Check the operation of the first and reverse brake piston Apply compressed air into the case passage and confirm...
  • Page 48 AT-29 AUTOMATIC TRANSAXLE Removal of Component Parts Remove the flange, seven discs and seven plates. HINT: For the method of inspection, refer to AT-66. AT3565 TURN TRANSAXLE CASE AROUND REMOVE OVERDRIVE UNIT Remove the thirteen bolts. AT4169 Tap on the circumference of the overdrive case with a plastic hammer to remove the overdrive case and gasket.
  • Page 49 AT-30 AUTOMATIC TRANSAXLE Removal of Component Parts Remove the overdrive clutch apply gasket and overdrive brake apply gasket. AT4168 REMOVE FIRST AND REVERSE BRAKE PISTON Remove the piston return spring. Place SST, and compress the return spring evenly by tightening the bolt gradually. 09350-32014 (09351-32040) AT0376 Using snap ring pliers, remove the snap ring.
  • Page 50 AT-31 AUTOMATIC TRANSAXLE Removal of Component Parts Remove the two O-rings from the piston. AT2725 REMOVE SNAP RING FROM TRANSAXLE CASE AT3572 REMOVE PARKING LOCK PAWL BRACKET AT0147 REMOVE MANUAL VALVE SHAFT Using a cold chisel and hammer, cut the collar. AT3573 Remove the retaining spring.
  • Page 51 AT-32 AUTOMATIC TRANSAXLE Removal of Component Parts Using a hammer and pin punch, drive out the pin. AT3574 Slide out the shaft from the transaxle case and remove the manual valve lever and parking lock rod. AT3576 REMOVE MANUAL VALVE SHAFT OIL SEAL Using a screwdriver, remove the oil seal.
  • Page 52 AT-33 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVAL OF DIFFERENTIAL COMPONENT PARTS MEASURE DIFFERENTIAL TOTAL PRELOAD Using a torque meter measure the total preload, and make a note of it. AT4171 REMOVE LH BEARING RETAINER Remove the six bolts. AT4170 Using a large screwdriver, remove the LH bearing retainer.
  • Page 53 AT-34 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE CARRIER COVER A540E Remove the eleven bolts. AT3583 A540H AT4173 Tap the carrier cover with a plastic hammer to A540E remove it. AT3584 A540H AT4232 REMOVE DIFFERENTIAL CASE A540E (A540E) Remove the differential case, outer race and shim from the transaxle case.
  • Page 54 AT-35 AUTOMATIC TRANSAXLE Removal of Component Parts (A540H) A540H Remove the differential assembly. AT4176 Remove the two apply gaskets. A540H AT4601 REMOVE DRIVE PINION CAP Remove the bolt. AT3586 Using pliers, pull out the drive pinion cap. Remove the O-rings from the cap. AT3587 MEASURE DRIVE PINION PRELOAD Using a torque meter, measure the drive pinion preload.
  • Page 55 AT-36 AUTOMATIC TRANSAXLE Removal of Component Parts REMOVE COUNTER DRIVEN GEAR Using a chisel, loosen the staked part of the nut. AT3589 Using SST to hold the gear, remove the nut. 09330-00021,09350-32014 (09351-32032) AT3590 Using SST, remove the gear and bearing. 09350-32014 (09351-32061) AT3591 REMOVE OUTER RACE, SPACER AND OIL SLINGER...
  • Page 56 AT-37 AUTOMATIC TRANSAXLE Removal of Component Parts (A540E) A540E REMOVE SENSOR ROTOR AT3594 (A540H) A540H REMOVE DRIVE PINION BEARING NO. 2 SPACER AT4175 REMOVE DRIVE PINION Using SST, remove the snap ring. 09350-32014 (09351-32050) AT3595 Insert the bar into the case hole to drive out the drive pinion.
  • Page 57 AT-38 AUTOMATIC TRANSAXLE Removal of Component Parts Remove the bearing cage from drive pinion. AT3605...

  • Page 58: Oil Pump

    AT-43 AUTOMATIC TRANSAXLE Component Parts (Oil Pump) Oil Pump COMPONENTS 100 (7, 10) Stator Shaft Pump Body Driven Gear Oil Seal Ring Thrust Washer Drive Gear Oil Seal O-Ring kg-cm (ft-lb, N-m) : Specified torque Non-reusable part AT3608 DISASSEMBLY OF OIL PUMP REMOVE OIL SEAL RINGS Remove the two oil seal rings from the stator shaft back side.
  • Page 59 AT-44 AUTOMATIC TRANSAXLE Component Parts (Oil Pump) REMOVE STATOR SHAFT Remove the eleven bolts and stator shaft. HINT: Keep the gears in assembly order. AT3611 REMOVE FRONT OIL SEAL Pry off the oil seal with a screwdriver. AT2732 INSPECTION OF OIL PUMP CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body.
  • Page 60 AT-45 AUTOMATIC TRANSAXLE Component Parts (Oil Pump) There are three different thicknesses for drive and driven gears. Drive and driven gear thickness Mark Thickness 9.440 - 9.456 mm (0.3717 - 0.3723 in.) 9.456 - 9.474 mm (0.3723 - 0.3730 in.) 9.474 - 9.490 mm (0.3730 - 0.3736 in.) If the thickest gear can not make the side clearance within standard specification, replace the oil pump body...
  • Page 61 AT-46 AUTOMATIC TRANSAXLE Component Parts (Oil Pump) INSTALL STATOR SHAFT TO PUMP BODY Align the stator shaft with each bolt hole. Torque the eleven bolts. Torque: 100 kg-cm (7 ft-lb, 10 N-m) AT3611 INSTALL THRUST WASHER Coat the thrust washer with petroleum jelly. Align the tab of the washer with the hollow of the pump body.
  • Page 62 AT-47 AUTOMATIC TRANSAXLE Component Parts (Direct Clutch) Direct Clutch COMPONENTS Piston Return Spring Snap Ring O-Ring Piston Clutch Drum Thrust Washer Snap Ring Flange Disc Plate Non-reusable part AT3613 DISASSEMBLY OF DIRECT CLUTCH CHECK PISTON STROKE OF DIRECT CLUTCH Install the direct clutch on the oil pump. Using a dial indicator (long type pick or SST), measure the direct clutch piston stroke applying and releasing the compressed air (4 - 8 kg/cm...
  • Page 63 AT-48 AUTOMATIC TRANSAXLE Component Parts (Direct Clutch) REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES AT0163 REMOVE PISTON RETURN SPRING Place SST on the spring retainer and compress the springs with a shop press. 09350-32014 (09351-32070) Remove the snap ring with snap ring pliers. AT2733 Remove the piston return spring.
  • Page 64 AT-49 AUTOMATIC TRANSAXLE Component Parts (Direct Clutch) INSPECTION OF DIRECT CLUTCH INSPECT CLUTCH PISTON Check that the check ball is free by shaking the piston. Check that the valve does not leak by applying low-pressure compressed air. AT3615 AT3616 INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt.
  • Page 65 AT-50 AUTOMATIC TRANSAXLE Component Parts (Direct Clutch) Place SST on the spring retainer, and compress the return spring with a shop press. 09350-32014 (09351-32070) Install the snap ring using snap ring pliers. Be sure the end gap of snap ring is not aligned with the spring retainer claw.
  • Page 66 AT-51 AUTOMATIC TRANSAXLE Component Parts (Forward Clutch) Forward Clutch COMPONENTS Return Spring O-Ring Bearing Piston Bearing Clutch Drum Oil Seal Ring Snap Ring Spring A540H Retainer Disc A540H Snap Ring Flange Non-reusable part Plate AT4342 DISASSEMBLY OF FORWARD CLUTCH CHECK PISTON STROKE OF FORWARD CLUTCH Using a dial indicator (long type pick or SST), measure the forward clutch piston stroke applying and releasing the compressed air (4 - 8 kg/cm...
  • Page 67 AT-52 AUTOMATIC TRANSAXLE Component Parts (Forward Clutch) A540H AT4341 REMOVE SNAP RING FROM CLUTCH DRUM A70176 REMOVE FLANGE, DISCS AND PLATES AT2738 REMOVE RETURN SPRING Place SST on the spring retainer and compress the springs with a shop press. 09350-32014 (09351-32070) Remove the snap ring using snap ring pliers.
  • Page 68 AT-53 AUTOMATIC TRANSAXLE Component Parts (Forward Clutch) (A540H) A540H Spring Retainer Remove the spring retainer and eighteen return springs. AT2797 REMOVE CLUTCH PISTON A540E Apply compressed air into the oil passage to re- move the piston. If the piston does not come out, use needle-nose pliers to remove it.
  • Page 69 AT-54 AUTOMATIC TRANSAXLE Component Parts (Forward Clutch) (A540H) A540H Remove the two oil seal rings from the shaft. Oil Seal Ring AT4340 INSPECTION OF FORWARD CLUTCH INSPECT CLUTCH PISTON Check that the check ball is free by shaking the piston. Check that the valve does not leak by applying low-pressure compressed air.
  • Page 70 AT-55 AUTOMATIC TRANSAXLE Component Parts (Forward Clutch) Coat the O-rings with ATF. Press the piston into the drum with the cup side up, being careful not to damage the O-rings. AT0182 INSTALL PISTON RETURN SPRINGS Place the return spring and snap ring onto the piston.
  • Page 71 AT-56 AUTOMATIC TRANSAXLE Component Parts (Forward Clutch) If the piston stroke is nonstandard, select another flange. A540E HINT: There are two different thicknesses for the flange. Flange thickness: 3.00 mm (0.1181 in.) 3.37 mm (0.1327 in.) AT3620 A540H AT4341...
  • Page 72 AT-57 AUTOMATIC TRANSAXLE Component Parts (Front Planetary Gear) Front Planetary Gear COMPONENTS Thrust Washer (A540E only) Thrust Washer Sun Gear Input Drum Sun Gear Planetary Gear Ring Gear Ring Gear Flange No. 1 One-Way Clutch Snap Ring Bearing Bearing Snap Ring AT3747 DISASSEMBLY OF NO.
  • Page 73 AT-58 AUTOMATIC TRANSAXLE Component Parts (Front Planetary Gear) REMOVE THRUST WASHER FROM SUN GEAR INPUT DRUM AT3628 REMOVE SUN GEAR FROM DRUM Using snap ring pliers, remove the snap ring from the drum. Remove the sun gear from the drum. AT2739 CHECK SUN GEAR BUSHINGS Using a dial indicator, measure the inside diameter of...
  • Page 74 AT-59 AUTOMATIC TRANSAXLE Component Parts (Front Planetary Gear) INSTALL NO. 1 ONE-WAY CLUTCH ON SUN GEAR Lock While turning the hub clockwise, slide the No. 1 one- way clutch onto the sun gear. Free Hold Turn RECHECK OPERATION OF NO. 1 ONE-WAY CLUTCH AT0185 INSPECTION OF PLANETARY RING GEAR INSPECT RING GEAR FLANGE BUSHING...
  • Page 75 AT-60 AUTOMATIC TRANSAXLE Component Parts (Front Planetary Gear) INSPECTION OF FRONT PLANETARY GEAR MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16 - 0.56 mm (0.0063 - 0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater than the maximum, replace...
  • Page 76 AT-61 AUTOMATIC TRANSAXLE Component Parts (Second Brake) Second Brake COMPONENTS Flange Disc Plate O-Ring Second Brake Drum Snap Ring See page AT-135 Piston Return Spring Piston Second Brake Drum Gasket Non-reusable part AT3630 DISASSEMBLY OF SECOND BRAKE PISTON REMOVE SECOND BRAKE PISTON Apply compressed air to the oil hole to remove the piston.
  • Page 77 AT-62 AUTOMATIC TRANSAXLE Component Parts (Second Brake) INSPECTION OF SECOND BRAKE COMPONENT INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and Printed flange are worn or burnt. If necessary, replace them. Numbers HINT: If the lining of the disc is exfoliated or discolored, or even a part of the printed numbers are de- faced, replace all discs.
  • Page 78 AT-63 AUTOMATIC TRANSAXLE Component Parts (Rear Planetary Gear) Rear Planetary Gear COMPONENTS Snap Ring Ring Gear Rear Planetary Gear Thrust Washer (A540H Only) Outer Race No. 2 One-Way Clutch Flange Bearing Thrust Washer Snap Ring Retainer Retainer Snap Ring AT4474 DISASSEMBLY OF NO.
  • Page 79 AT-64 AUTOMATIC TRANSAXLE Component Parts (Rear Planetary Gear) REMOVE NO. 2 ONE-WAY CLUTCH FROM OUTER RACE Remove the two snap rings and retainers from both sides. Remove the No. 2 one-way clutch from the outer race. AT0192 INSPECTION OF REAR PLANETARY GEAR MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion...
  • Page 80 AT-65 AUTOMATIC TRANSAXLE Component Parts (Rear Planetary Gear) INSTALL PLANETARY GEAR INTO NO. 2 ONE-WAY CLUTCH Black Side Install the planetary gear into the No. 2 one-way clutch, facing the inner race of the rear planetary gear toward the black side of the No. 2 one-way clutch outer race. AT0649 CHECK OPERATION OF NO.
  • Page 81 AT-66 AUTOMATIC TRANSAXLE Component Parts (First and Reverse Brake) First and Reverse Brake COMPONENTS A540E Plate Disc Flange Snap Ring O-Ring Piston Piston Return Spring See page AT-133 Snap Ring Non-reusable part AT3632 INSPECTION OF FIRST AND REVERSE BRAKE COMPONENTS INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and Printed...
  • Page 82 AT-67 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) Overdrive Unit COMPONENTS O/D Brake Piston Flange O-Ring O/D Brake Drum Piston Return Spring Oil Seal Ring Disc Drum Plate Cushion Plate O-Ring Snap Ring O/D Case Piston Disc Snap Ring Race Bearing Bearing O-Ring Piston Return...
  • Page 83 AT-68 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) DISASSEMBLY OF OVERDRIVE BRAKE REMOVE PISTON RETURN SPRING While pushing the return spring, remove the snap ring with a screwdriver. Remove the piston return spring. AT3063 REMOVE PLATES, DISCS AND FLANGE AT2523 REMOVE PISTON FROM DRUM Apply compressed air to oil hole to remove the piston.
  • Page 84 AT-69 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) DISASSEMBLY OF OVERDRIVE DIRECT CLUTCH CHECK PISTON STROKE OF DIRECT CLUTCH Using a dial indicator, measure the piston stroke while applying and releasing the compressed air (4 - 8 kg/ , 57 - 114 psi or 392 - 785 kPa) as shown. Piston stroke: 1.75 - 2.49 mm (0.0689 - 0.0980 in.) 09350-32014 (09351-32190)
  • Page 85 AT-70 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) REMOVE PISTON RETURN SPRING Place SST on the spring retainer and compress the spring with a shop press. 09350-32014 (09351-32070, 09351-32200) Remove the snap ring. AT3635 Remove the piston return spring. AT3636 REMOVE PISTON FROM CLUTCH DRUM Install the clutch drum on the case.
  • Page 86 AT-71 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is exfoliated or discolored, Printed or even a part of the printed numbers are de- Numbers...
  • Page 87 AT-72 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) Place SST on the spring retainer, and compress the spring with a shop press. 09350-32014 (09351-32070, 09351-32200) Install the snap ring with a screwdriver. Be sure end gap of snap ring is aligned with the groove of the clutch drum.
  • Page 88 AT-73 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSTALL DIRECT CLUTCH ON CASE AT7721 RECHECK PISTON STROKE OF DIRECT CLUTCH Using a dial indicator, measure the piston stroke while applying and releasing the compressed air (4 - 8 kg/ , 57 - 114 psi or 392 - 785 kPa) as shown. Piston stroke: 1.75 - 2.49 mm (0.0689 - 0.0980 in.)
  • Page 89 AT-74 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) REMOVE O/D ONE-WAY CLUTCH AND OUTER RACE Remove the snap ring. AT3647 Remove the retaining plate. Remove the O/D one-way clutch with outer race. Retaining Plate O/D One-Way Clutch with Outer Race AT3648 Remove the two retainers from both sides of the O/D one-way clutch.
  • Page 90 AT-75 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) REMOVE ADJUSTING NUT AND LOCKING WASHER Pry off the locking washer. AT3650 Using SST, loosen the adjusting nut. 09350-32014 (09351-32080) Remove the adjusting nut and locking washer. AT3651 REMOVE INTERMEDIATE SHAFT BEARING Using SST, press out the bearing from the shaft. 09950-00020 AT3652 REMOVE COUNTER DRIVE GEAR AND FRONT...
  • Page 91 AT-76 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) Tag the bearings to show the location for reas- sembly. AT4431 REMOVE OVERDRIVE PLANETARY RING GEAR FROM COUNTER DRIVE GEAR While pulling up the ring gear, compress the snap ring with needle-nose pliers and remove it from the groove.
  • Page 92 AT-77 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) REMOVE SNAP RING FROM COUNTER DRIVE GEAR Using a screwdriver, remove the snap ring. AT3657 INSPECTION OF OVERDRIVE PLANETARY GEAR MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance.
  • Page 93 AT-78 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSTALL OVERDRIVE PLANETARY RING GEAR INTO COUNTER DRIVE GEAR Install the snap ring to the ring gear. AT3655 While pushing down the ring gear, squeeze the snap ring end with needle-nose pliers, and install it into the groove.
  • Page 94 AT-79 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSTALL INTERMEDIATE SHAFT BEARING Using SST, press in the bearing until it slightly touches the front bearing of the counter drive gear. 09350-32014 (09351-32120) HINT: The counter drive gear can be turned lightly. AT3663 PLACE NEW LOCKING WASHER Washer...
  • Page 95 AT-80 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSTALL OVERDRIVE ONE-WAY CLUTCH AND RETAINING PLATE Install the one-way clutch into the outer race. AT0426 Install the two retainer on both sides of the one- way clutch. AT3649 Install the one-way clutch into the overdrive plane- tary gear.
  • Page 96 AT-81 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) DISASSEMBLY OF OVERDRIVE CASE REMOVE C ACCUMULATOR PISTON FROM OVERDRIVE CASE Using snap ring pliers, remove the snap ring. AT3668 Remove the retaining plate and two springs. Plate Remove the accumulator piston. Piston AT3669 Remove the O-ring from the piston.
  • Page 97 AT-82 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSTALL C ACCUMULATOR PISTON TO OVERDRIVE CASE Install a new O-ring to the accumulator piston. Coat the O-ring with ATF. AT3671 Install the accumulator piston, two springs and Plate retaining plate. Piston AT3669 Using snap ring pliers, install the snap ring.
  • Page 98 AT-83 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) INSTALL FLANGE, DISCS AND PLATES Install the flange, discs and plates. Install in order: P = Plate D = Disc Flange-D-P-D-P-D-P Plate Disc Flange AT3672 Install the cushion plate with the rounded end facing upward.
  • Page 99 AT-84 AUTOMATIC TRANSAXLE Component Parts (Overdrive Unit) HINT: If the overdrive planetary gear is properly installed onto the direct clutch, the counter drive gear height from the overdrive case will be about 24 mm (0.94 in.). AT7731...
  • Page 100 AT-85 AUTOMATIC TRANSAXLE Component Parts (Valve Body) Valve Body COMPONENTS No. 1 and No. 2 Solenoids Oil Strainer 67 (58 in.-lb. 6.6) Upper Valve Body No. 1 Gasket Cover O-Ring No. 1 Plate Gasket Plate No. 2 Gasket Check Ball Gasket Upper Valve Body Lock-Up Solenoid...
  • Page 101 AT-86 AUTOMATIC TRANSAXLE Component Parts (Valve Body) REMOVE B ACCUMULATOR ASSEMBLY Remove the three bolts. Accumulator Remove the B accumulator assembly. Remove the check ball on No. 1 plate. Check Ball AT3464 DISASSEMBLE B ACCUMULATOR ASSEMBLY Applying compressed air to the cylinder hole, remove the piston and spring.
  • Page 102 AT-87 AUTOMATIC TRANSAXLE Component Parts (Valve Body) REMOVE LOWER VALVE BODY COVER Remove the twelve bolts and lower valve body cover. AT3470 REMOVE LOWER VALVE BODY COVER GASKETS AND NO. 2 PLATE Gasket Plate AT3471 REMOVE CHECK BALLS Remove the two check balls from the lower valve body. AT3472 REMOVE BOLT FROM LOWER VALVE BODY AT3473...
  • Page 103 AT-88 AUTOMATIC TRANSAXLE Component Parts (Valve Body) LIFT OFF UPPER VALVE BODY AND NO. 1 PLATE AS A SINGLE UNIT Hold No. 1 plate to the upper valve body and lift off the upper valve body. HINT: Be careful that the check balls and oil strainer do not fall out.
  • Page 104 AT-89 AUTOMATIC TRANSAXLE Component Parts (Valve Body) (Upper Valve Body) COMPONENTS Adjusting Ring The throttle pressure is changed according to the number of adjusting rings. When assembling the valve body, install the same number of adjusting rings as were removed. 2nd Coast Modulator Valve Retainer...
  • Page 105 AT-90 AUTOMATIC TRANSAXLE Component Parts (Valve Body) SPECIFICATIONS OF VALVE BODY SPRINGS Coil outer diameter Spring Free length mm (in.) Total No. of coils Color mm (in.) Second coast modulator valve 27.5 (1.083) 8.9 (0.350) 14.6 Brown 24.8 (0.976) orifice control valve 8.0 (0.315) 12.0 White...
  • Page 106 AT-91 AUTOMATIC TRANSAXLE Component Parts (Valve Body) LOCATION OF RETAINERS, PIN, STOPPER, CHECK BALL AND STRAINER RETAINER, STOPPER AND PIN (Upper Side) (Lower Side) Valve Vibrating Stopper AT3479 AT3478 mm (in.) Width Thickness Height Retainer Lock-up relay valve (0.126) (0.197) (0.256) Throttle modulator valve (0.197)
  • Page 107 AT-92 AUTOMATIC TRANSAXLE Component Parts (Valve Body) (Lower Valve Body) COMPONENTS Check Ball Pressure Relief Valve Check Valve Oil Strainer Secondary Regulator Valve Check Ball No. 2 Accumulator Retainer Control Valve 2nd lock Valve Plug Retainer Plug Retainer Plug 3 - 4 Shift Valve Plug Retainer Low Coast Modulator Valve...
  • Page 108 AT-93 AUTOMATIC TRANSAXLE Component Parts (Valve Body) SPECIFICATIONS OF VALVE BODY SPRINGS Coil outer diameter Spring Free length mm (in.) Total No. of coils Color mm (in.) 11.2 (0.441) 6.4 (0.252) Pressure relief valve None 19.9 (0.783) 11.0 (0.433) Check valve None 38.5 (1.516) 8.4 (0.331)
  • Page 109 AT-94 AUTOMATIC TRANSAXLE Component Parts (Valve Body) LOCATION OF RETAINERS, CHECK BALLS AND STRAINERS RETAINER (Lower Side) (Upper Side) AT3484 AT3485 mm (in.) Retainer Height Width Thickness Primary regulator valve (0.362) (0.197) (0.126) 15.0 Secondary regulator valve (0.591) (0.197) (0.126) No.
  • Page 110 AT-95 AUTOMATIC TRANSAXLE Component Parts (Valve Body) (Assembly of Valve Body) (See page AT-85) No. 2 Gasket POSITION NO. 1 PLATE AND NEW GASKETS ON No. 1 Plate UPPER VALVE BODY No. 1 Gasket Position new No. 1 gasket, No. 1 plate and then new No.
  • Page 111 AT-96 AUTOMATIC TRANSAXLE Component Parts (Valve Body) INSTALL LOCK-UP RELAY VALVE SLEEVE STOPPER AT3469 INSTALL UPPER VALVE BODY COVER GASKETS, Oil Strainer PLATE AND THROTTLE MODULATOR OIL STRAINER Position a new gasket and plate and then another new gasket Gasket HINT: Both gaskets are same one.
  • Page 112 AT-97 AUTOMATIC TRANSAXLE Component Parts (Valve Body) INSTALL LOWER VALVE BODY COVER GASKETS AND NO. 2 PLATE Position a new gasket and plate and then another new gasket. HINT: Both gaskets are same one. Gasket Plate Gasket AT3471 INSTALL LOWER VALVE BODY COVER Position the lower valve body cover.
  • Page 113 AT-98 AUTOMATIC TRANSAXLE Component Parts (Valve Body) Plate the check ball on No. 1 gasket. Install the B accumulator assembly. Install and torque the three bolts. HINT: Each bolt length (mm, in.) is indicated in the figure. Torque: 67 kg-cm (58 in.-lb, 6.6 N-m) AT3464 INSTALL SOLENOIDS Coat new O-rings with ATF and install them to...
  • Page 114 AT-99 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) Differential Assembly (A540E) COMPONENTS Drive Pinion Bearing Outer Race Bearing Cage O-Ring Oil Seal Snap Ring Sensor Rotor Spacer Oil Slinger 195 (14, 19) Outer Race Oil Seal Bearing Counter Driven Gear RN Retainer 640 (46, 63) Shim Outer Race...
  • Page 115 AT-100 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) DISASSEMBLY OF DIFFERENTIAL CASE REMOVE SIDE BEARING Using SST, remove the two side bearings. 09950-20017 AT7732 REMOVE RING GEAR Place the matchmarks on both the differential case and ring gear. Matchmarks AT7733 Remove the sixteen bolts. AT7734 Using a plastic hammer, tap out the ring gear.
  • Page 116 AT-101 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) Using a torx wrench, remove the sixteen torx screws. AT7737 Using a plastic hammer, tap out the differential left case. Remove the speedometer drive gear from the differential right case. AT7738 Remove the two differential side gears, two side thrust washers, differential spider, four differential pinions and four pinion washers from the differential left case.
  • Page 117 AT-102 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) REMOVE RH OIL SEAL FROM RH RETAINER Using a hammer and screwdriver, drive out the oil seal. AT3677 ASSEMBLY OF DIFFERENTIAL CASE INSTALL RH OIL SEAL TO RH RETAINER Using SST, drive in a new oil seal until its surface is flush with the surface of RH retainer.
  • Page 118 AT-103 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) Install the four pinions and thrust washers to the spider. Install the side gear and spider with four pinions to the differential left case. AT7741 Using a dial indicator, measure the backlash of one pinion gear while holding the side gear.
  • Page 119 AT-104 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) Using a plastic hammer, carefully tap the differential right case. AT7745 Using a torx wrench, install and torque the sixteen torx screws. Torque: 640 kg-cm (46 ft-lb, 63 N-m) AT7746 INSTALL RING GEAR Clean the contact surface of the differential case.
  • Page 120 AT-105 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E) Using SST and a press, install the LH side bearing. 09316-60010 (09316-00010) AT3682...
  • Page 121 AT-106 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) Differential Assembly (A540H) COMPONENTS Snap Ring Counter Driven Gear Spacer Outer Race Drive Pinion Bearing Outer Race Piston Return Bearing Cage Spring Drive Pinion No. 2 Spacer O-Ring Snap Ring Oil Slinger O-Ring Bearing Ring Gear Mounting...
  • Page 122 AT-107 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) DISASSEMBLY OF DIFFERENTIAL ASSEMBLY Outer Race REMOVE RIGHT SIDE BEARING OUTER RACE AT4299 CHECK DIFFERENTIAL END PLAY Using a dial indicator, measure the differential end play. End play: 0.18 - 0.82 mm (0.0071 - 0.0323 in.) AT4300 REMOVE RING GEAR MOUNTING CASE SLEEVE Sleeve...
  • Page 123 AT-108 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) REMOVE RING GEAR MOUNTING LEFT CASE Place matchmarks on the ring gear mounting left case and right case. Remove the twelve bolts and left case. Matchmarks AT4297 REMOVE RING GEAR Place matchmarks on the ring gear and left case. Matchmarks AT4337 Place the left case on SST.
  • Page 124 AT-109 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) REMOVE FRONT DIFFERENTIAL LEFT CASE Using a torx wrench, remove the sixteen screws from the left case. Separate the left case and right case. NOTICE: Do not scratch the contact surface of the needle bearing.
  • Page 125 AT-1 10 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) Remove the flange, eleven discs and eleven plates. AT4311 Place SST, and compress the return spring. 09350-32014 (09351-32070) Using snap ring pliers, remove the snap ring. AT4316 Apply compressed air to the right case hole to remove the No.
  • Page 126 AT-1 11 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) INSTALL RING GEAR MOUNTING LEFT CASE BEARING Using a press and SST, press in the bearing. 09316-2001 1, 09350-32014 (09351-32090) AT4334 REMOVE RING GEAR MOUNTING RIGHT CASE BEARING Using a chisel and hammer, cut out the bearing cage.
  • Page 127 AT-1 12 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) Using a hammer and brass bar, drive out the outer race and adjusting shim from LH bearing retainer. AT3676 INSTALL ADJUSTING SHIM AND BEARING OUTER RACE TO LH BEARING RETAINER Place the adjusting shim into the LH bearing retainer.
  • Page 128 AT-1 13 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) ASSEMBLY OF DIFFERENTIAL ASSEMBLY INSTALL PISTONS AND SLEEVE Coat the four O-rings with ATF. Install the four O-rings to the reaction sleeve and pistons. AT4318 Install the No. 1 (A), No. 2 (B) pistons and reac- tion sleeve (C) to the ring gear mounting right case.
  • Page 129 AT-1 14 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) Using a screwdriver, install the snap ring. AT7755 CHECK OPERATION OF CLUTCH PISTONS Plug one hole with your hand. Apply compressed air into the other hole and make sure that the pistons move. AT4320 INSTALL NO.
  • Page 130 AT-1 15 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) (Front Differential Right Case) Install the following parts: S Side gear thrust washer S Side gear S Four differential pinion gears S Four pinion gear thrust washers S Differential spider AT4603 Using a dial indicator, measure the backlash of one pinion gear while holding the side gear to- ward the case.
  • Page 131 AT-1 16 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) INSTALL FRONT DIFFERENTIAL CASE Install the front differential case to the ring gear mounting right case. HINT: Align the flukes of the discs in the hydraulic multi- plate clutch. AT4429 Install the No. 2 thrust washer. AT4317 INSTALL RING GEAR 212°F (100°C)
  • Page 132 AT-1 17 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) CHECK OPERATION OF FRONT DIFFERENTIAL Check that the front differential turns smoothly. AT7757 INSTALL SPEEDOMETER DRIVE GEAR Place the speedometer drive gear on the ring gear mounting case. Install the snap ring. AT7758 INSTALL OIL SEAL RINGS Install the four oil seal rings to the ring gear mounting...
  • Page 133 AT-1 18 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) DISASSEMBLY OF DRIVE PINION REMOVE DRIVE PINION SHAFT BEARING Using SST and a press, remove the bearing. 09950-00020 TA0043 (A540E) A540E REMOVE OIL SEALS FROM CAGE Using SST, press out the two oil seals. 09325-12010 AT3683 REMOVE PINION SHAFT BEARING OUTER RACE...
  • Page 134 AT-1 19 AUTOMATIC TRANSAXLE Component Parts (Differential Assembly-A540E, A540H) (A540E) A540E INSTALL OIL SEALS TO CAGE Using SST, press in a new oil seal with the lip facing downward. 09325-12010 Oil seal press in depth (from flat end): 8 mm (0.31 in.) AT3685 Check the oil seal press in depth.
  • Page 135 TF-2 TRANSFER (A540H) Component Parts Transfer (A540H) COMPONENT PARTS 300 (22, 29) Transfer Right Case Retainer 115 (8, 11) O-Ring Lever Guide 73 (63 in.-lb, 7.2) Mode Select Lever Dawel Pin and Rod 55 (48 in.-lb, 5.4) Apply Gasket Oil Pump Driven Gear O-Ring O-Ring Adjusting Nut Lock Pate...
  • Page 136 AT-120 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALLATION OF COMPONENT PARTS Disassembly, inspection and assembly of each component group have been indicated in the pre- ceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
  • Page 137 AT-121 AUTOMATIC TRANSAXLE Installation of Component Parts Be sure to install the thrust bearings and races in the correct direction and position. AT5039 mm (in.) A540E Outer See page 47.6 45.5 38.7 54.0 AT-354 Diameter (1.874) (1.791) (1.524) (2.126) Bearing (with race) Inner 27.7...
  • Page 138 AT-122 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALLATION OF DIFFERENTIAL AND DRIVE PINION INSTALL DRIVE PINION INTO TRANSAXLE CASE Place the bearing cage onto the drive pinion shaft. NOTICE: Be careful not to damage the oil seals with the pinion shaft. (A540E) AT3605 Install the two new O-rings to the bearing cage.
  • Page 139 AT-123 AUTOMATIC TRANSAXLE Installation of Component Parts (A540H) A540H Spacer INSTALL DRIVE PINION BEARING NO. 2 SPACER AT4175 PLACE OIL SLINGER AND NEW SPACER Spacer HINT: Install the spacer with the small end downward. Oil Slinger AT3593 INSTALL OUTER RACE TO TRANSAXLE CASE Using SST, press in the outer race.
  • Page 140 AT-124 AUTOMATIC TRANSAXLE Installation of Component Parts Turn the gear counterclockwise and clockwise sev- eral times. 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.-lb, 1.0 - 1.6 N-m) Reused bearing AT3588 5 - 8 kg-cm...
  • Page 141 AT-125 AUTOMATIC TRANSAXLE Installation of Component Parts (A540H) A540H Sleeve Be sure to install the ring gear mount case sleeve and outer race into place. AT4965 INSTALL CARRIER COVER A540E Remove any packing material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case.
  • Page 142 AT-126 AUTOMATIC TRANSAXLE Installation of Component Parts A540H AT4173 ADJUST SIDE SEARING PRELOAD Remove any packing material on the contacting surfaces of the LH bearing retainer and transaxle case. HINT: Do not apply seal packing yet. Install the LH bearing retainer and torque the six bolts.
  • Page 143 AT-127 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL LH BEARING RETAINER Remove the six bolts and LH bearing retainer. AT4170 Remove any packing material on the contacting surfaces of LH bearing retainer, transaxle case and carrier cover. Apply the seal packing to the transaxle case and carrier cover as shown.
  • Page 144 AT-128 AUTOMATIC TRANSAXLE Installation of Component Parts (A540E) A540E INSTALL RH RETAINER Remove any packing material on the contacting Seal surfaces of RH retainer and transaxle case. Packing Apply the seal packing to the RH retainer as shown. Seal packing: Part No.
  • Page 145 AT-129 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALLATION OF 4-SPEED GEAR UNIT INSTALL PARKING LOCK PAWL Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl. Install the pin into the hole of the case through the spring and pawl.
  • Page 146 AT-130 AUTOMATIC TRANSAXLE Installation of Component Parts Match the collar hole to the lever calking hollow and calk the collar to the lever. AT0093 Install the retaining spring. Retaining Spring AT5025 INSTALL PARKING LOCK PAWL BRACKET Torque: 75 kg-cm (65 in.-lb, 7.4 N-m) AT0312 CHECK OPERATION OF PARKING LOCK PAWL Make sure the counter driven gear is locked when the...
  • Page 147 AT-131 AUTOMATIC TRANSAXLE Installation of Component Parts Push the piston into the bore of the case, facing the spring seat upward. AT0197 INSTALL PISTON RETURN SPRING Place the return spring and snap ring on the piston. Place SST, and compress the return spring evenly by tightening the bolt gradually.
  • Page 148 AT-132 AUTOMATIC TRANSAXLE Installation of Component Parts Install the overdrive brake drum to the case. Install the new case gasket to the case. AT2728 Make sure that the length from the top surface of the case to the counter driven gear top surface should be about 24 mm (0.94 in.) AT7731 Place the new gasket onto the transaxle case.
  • Page 149 AT-133 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL REAR PLANETARY GEAR A540E Install the rear planetary ring gear. A540H (A540E) Place the bearing onto the ring gear. (A540H) Coat the races and bearing with petroleum jelly and install them onto the ring gear. Bearing and race: mm (in.) Outer Diameter...
  • Page 150 AT-134 AUTOMATIC TRANSAXLE Installation of Component Parts CHECK FIRST AND REVERSE BRAKE Check the operation of the first and reverse brake piston. Apply compressed air into the case passage and confirm that the piston moves. AT3563 Using a filler gauge, check the pack clearance of the first and reverse brake.
  • Page 151 AT-135 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL SECOND COAST BRAKE BAND GUIDE AT3723 PLACE NO. 1 ONE-WAY CLUTCH A540E Coat the thrust washer with petroleum jelly and install it on the No. 1 one-way clutch. (A540E) AT3724 Place the No. 1 one-way clutch onto the rear planetary gear.
  • Page 152 AT-136 AUTOMATIC TRANSAXLE Installation of Component Parts Place the second brake drum into the case. HINT: Align the groove of the drum with the bolt. AT0334 Place the snap ring into the case so that end gap is installed into the groove. While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove.
  • Page 153 AT-137 AUTOMATIC TRANSAXLE Installation of Component Parts While turning the sun gear clockwise, install it into the No. 1 one-way clutch. AT3728 INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT HINT: After installing the oil seal ring, check that it moves smoothly. AT3730 INSTALL FRONT PLANETARY GEAR Coat the races and bearings with petroleum jelly, and...
  • Page 154 AT-138 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL SECOND COAST BRAKE BAND Place the band into the case. Install the pin through the oil pump mounting bolt hole. AT0346 INSTALL FORWARD CLUTCH AND DIRECT CLUTCH Coat the race and bearing with petroleum jelly and install it onto rear side of the forward clutch.
  • Page 155 AT-139 AUTOMATIC TRANSAXLE Installation of Component Parts Install the direct clutch and forward clutch into the case. HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place. AT3547 Check the distance between the direct clutch drum and the sun gear input drum.
  • Page 156 AT-140 AUTOMATIC TRANSAXLE Installation of Component Parts CHECK INPUT SHAFT ROTATION Make sure that the input shaft rotates smoothly. Spring INSTALL SECOND COAST BRAKE PISTON Piston Coat the new O-rings with ATF and install it to the O-Rings cover. Install the outer spring with the piston. Place the cover into the bore.
  • Page 157 AT-141 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL ACCUMULATOR PISTONS AND SPRINGS Install the new O-rings to the pistons. Install the springs and pistons into the bores. Outer diameter Free length Color Spring mm (in.) mm (in.) 51.0 (2.008) 18.0 (0.709) 15.2 (0.598) 58.5 (2.303) Orange...
  • Page 158 AT-142 AUTOMATIC TRANSAXLE Installation of Component Parts Install and tighten the ten bolts. HINT: Each bolt length (mm, in.) is indicated in the figure. Hand tighten the ten bolts first, then torque with a torque wrench. Torque: 110 kg-cm (8 ft-lb, 11 N-m) AT4489 INSTALL B APPLY TUBE...
  • Page 159 AT-143 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL MANUAL VALVE BODY AND DETENT SPRING HINT: Each bolt length (mm, in.) is indicated in the figure. Align the manual valve with the pin on the manual shaft lever. Lower the manual valve body into place. Hand tighten the five bolts first.
  • Page 160 AT-144 AUTOMATIC TRANSAXLE Installation of Component Parts (A540E) A540E INSTALL SPEED SENSOR Install a new O-ring to the speed sensor. Install the speed sensor to the transaxle case. Tighten the bolt. Connect the sensor connector. AT3530 (A540H) A540H Speed Sensor INSTALL VEHICLE SPEED SENSOR Install a new O-ring to the vehicle speed sensor.
  • Page 161 AT-145 AUTOMATIC TRANSAXLE Installation of Component Parts INSTALL MANUAL SHIFT LEVER Manual Shift Lever AT3744 INSTALL UNION AND ELBOW A540H Install the new O-rings to the union and elbow. Install the union and elbow to the transaxle case. Torque: 275 kg-cm (20 ft-lb, 27 N-m) Union Elbow AT3527...
  • Page 162 AT-146 AUTOMATIC TRANSAXLE Installation of Component Parts (A540H) A540H INSTALL APPLY GASKET Install a new apply gasket to the differential carrier cover. AT4221 (A540H) A540H INSTALL TRANSFER ASSEMBLY Remove any packing material and be careful not to drop oil on the contacting surfaces of the transfer and transaxle.
  • Page 163 TF-3 TRANSFER (A540H) Disassembly of Component Parts DISASSEMBLY OF COMPONENT PARTS REMOVE TRANSFER MODE SELECT LEVER AND AT4309 REMOVE REAR WHEEL SPEED SENSOR Remove the bolt and pull out the speed sensor. Speed Sensor Remove the O-ring from speed sensor. AT4414 REMOVE DYNAMIC DAMPER Remove the four bolts and dynamic damper.
  • Page 164 TF-4 TRANSFER (A540H) Disassembly of Component Parts REMOVE TRANSFER RIGHT CASE RETAINER Remove the five bolts. Using a plastic hammer, remove the right case retainer. AT4333 Remove the O-ring and apply gasket from the right case retainer. Gasket O-ring AT4418 REMOVE TRANSFER INSPECTION HOLE COVER Remove the three bolts and inspection hole cover.
  • Page 165 TF-5 TRANSFER (A540H) Disassembly of Component Parts REMOVE DRIVEN PINION BEARING CAGE Remove the six bolts and bearing cage. O-ring Remove the O-ring and the shims from the bearing cage. Shim AT4421 REMOVE TRANSFER RIGHT CASE Remove the ten bolts and right case. AT4422 REMOVE CENTER DIFFERENTIAL ASSEMBLY AT4423...
  • Page 166 TF-6 TRANSFER (A540H) Disassembly of Component Parts REMOVE ADJUSTING NUT LOCK PLATE Lock Plate Remove the bolt and nut lock plate from the right case. Bolt Remove the O-ring from the bolt. AT4508 REMOVE DIFFERENTIAL RIGHT SIDE BEARING OUTER RACE Using SST, remove the adjusting nut and oil re- Adjusting Nut server from the right case.
  • Page 167 TF-7 TRANSFER (A540H) Component Parts (Driven Pinion Bearing Cage) Driven Pinion Bearing Cage COMPONENTS Front Side Bearing Driven Pinion Lock Nut 1,100 (80,108) *1,000 (72, 98) Union Rear Side Bearing Bearing Cage Transfer Pinion Spacer * For use SST kg-cm (ft-lb, N-m) : Specified torque Non-reusable part AT4323...
  • Page 168 TF-8 TRANSFER (A540H) Component Parts (Driven Pinion Bearing Cage) REMOVE DRIVEN PINION Using a press, remove the driven pinion, rear side bearing and spacer. AT7767 REMOVE FRONT SIDE BEARING Using a press and SST, remove the front side bearing. 09950-00020 AT7768 REMOVE BEARING OUTER RACES Using a brass bar and hammer, remove the two bearing...
  • Page 169 TF-9 TRANSFER (A540H) Component Parts (Driven Pinion Bearing Cage) INSTALL SPACER Install a new spacer to the driven pinion. AT7773 INSTALL DRIVEN PINION REAR SIDE BEARING Install the bearing cage to the driven pinion. Using a press and SST, install the rear side bearing to the driven pinion.
  • Page 170 TF-10 TRANSFER (A540H) Component Parts (Driven Pinion Bearing Cage) STAKE LOCK NUT Using a pin punch and hammer, stake the nut. AT7777...
  • Page 171 TF-1 1 TRANSFER (A540H) Component Parts (Transfer Right Case Retainer) Transfer Right Case Retainer COMPONENTS Holder Bearing Shaft Snap Ring Oil Seal Transfer Right Case Retainer Hole Snap Ring Differential Side Gear Shaft Oil Seal Holder Non-reusable part AT4324 DISASSEMBLY OF TRANSFER RIGHT CASE RETAINER REMOVE OIL SEAL Using a screwdriver, remove the oil seal.
  • Page 172 TF-12 TRANSFER (A540H) Component Parts (Transfer Right Case Retainer) Using a plastic hammer, remove the side gear shaft holder. AT4512 REMOVE HOLDER BEARING Using snap ring pliers, remove the snap ring. AT7778 Using a press, press out the bearing. AT3342 REMOVE OIL SEAL Using a screwdriver, remove the oil seal.
  • Page 173 TF-13 TRANSFER (A540H) Component Parts (Transfer Right Case Retainer) Using snap ring pliers, install the snap ring. AT7778 INSTALL SIDE GEAR SHAFT HOLDER Install the side gear shaft holder. AT4513 Using snap ring pliers, install the snap ring. AT7781 INSTALL OIL SEAL (Left side oil seal) Coat a new oil seal lip with MP grease.
  • Page 174 TF-14 TRANSFER (A540H) Component Parts (Transfer Right Case) Transfer Right Case COMPONENTS 250 (18, 25) O-Ring Compression Spring Relief Valve 80 (69 in.-lb, 7.8) Oil Pump Driven Rotor Oil Pump Drive Rotor Oil Pump Driven Gear Stopper O-Ring Oil Pump Cover Transfer Right Case Oil Pump Driven Gear Strainer...
  • Page 175 TF-15 TRANSFER (A540H) Component Parts (Transfer Right Case) REMOVE RELIEF VALVE Relief Valve Remove the relief valve and spring. ASSEMBLY OF TRANSFER RIGHT CASE INSTALL RELIEF VALVE Install the relief valve and spring. AT4515 INSTALL OIL PUMP DRIVE ROTOR AND DRIVEN ROTOR Align the matchmarks on the drive rotor and the driven rotor.
  • Page 176 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-16 Case and Center Differential Case) Ring Gear Mounting Case and Center Differential Case COMPONENTS Right Case Bearing Ring Gear Mounting Right Case O-Ring Ring Gear Mounting Left Case Transfer Ring Gear Left Case Shaft Snap Bearing Ring...
  • Page 177 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-17 Case and Center Differential Case) Remove oil pump drive gear. AT7782 REMOVE RING GEAR MOUNTING LEFT CASE Place matchmarks on the differential left case and the differential right case. Remove the twelve bolts. NOTICE: Using the soft jaws, hold the left case in a vise.
  • Page 178 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-18 Case and Center Differential Case) REMOVE THRUST WASHER AT7786 REMOVE CENTER DIFFERENTIAL CASE ASSEMBLY AT7787 DISASSEMBLE CENTER DIFFERENTIAL CASE Using snap ring pliers, remove the shaft snap ring. AT7788 Remove the spacer. AT7789...
  • Page 179 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-19 Case and Center Differential Case) Remove the following parts from the center differ- ential case: Four pinion shafts Pinion shaft holder Four differential pinions Four pinion thrust washers Differential side left gear Side gear thrust washer AT7790 REMOVE DIFFERENTIAL SIDE RIGHT GEAR AND...
  • Page 180 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-20 Case and Center Differential Case) INSTALL LEFT CASE BEARING Using SST and a press, press in the left case. 09316-12010, 09608-35014 (09608-06020, 09608-06120) AT7793 INSTALL RING GEAR Clean the contact surface of the ring gear mounting left case.
  • Page 181 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-21 Case and Center Differential Case) 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 differential case which comes in contact with the bushing.
  • Page 182 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-22 Case and Center Differential Case) Install the thrust washer. AT7786 Align the matchmarks on the ring gear mounting left and right case. Install and torque the twelve bolts. Torque: 985 kg-cm (71 ft-lb, 97 N-m) HINT: Do not install the O-ring.
  • Page 183 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-23 Case and Center Differential Case) INSTALL DIFFERENTIAL SIDE GEAR AND CONICAL SPRING WASHER HINT: Be careful not to make a mistake in the direction of the conical spring washer. AT7798 INSTALL CENTER DIFFERENTIAL CASE AT7787 INSTALL THRUST WASHER (Previously selected) AT7786...
  • Page 184 TRANSFER (A540H) Component Parts (Ring Gear Mounting TF-24 Case and Center Differential Case) Install the shaft snap ring. AT7800...
  • Page 185 TF-25 TRANSFER (A540H) Component Parts (Transfer Left Case) Transfer Left Case COMPONENTS 145 (10, 14) 70 (61 in.-lb, 6.9) O-ring Center Differential Control Solenoid 110 (8, 11) O-ring Transfer Valve Body Assembly Transfer Case Gasket Transfer Valve Body Gasket Differential Lock Sleeve Valve Body Strainer Transfer Shift Lever Head Plug...
  • Page 186 TF-26 TRANSFER (A540H) Component Parts (Transfer Left Case) DISASSEMBLY OF TRANSFER LEFT CASE REMOVE CENTER DIFFERENTIAL CONTROL SOLENOIDS Remove the four bolts and solenoid. AT4519 Remove the four O-rings from the solenoids. O-ring O-ring AT4520 REMOVE TRANSFER VALVE BODY ASSEMBLY Remove the eight bolts and transfer valve body assembly.
  • Page 187 TF-27 TRANSFER (A540H) Component Parts (Transfer Left Case) Using a screwdriver, remove the oil seal. AT4609 REMOVE SHIFT FORK SHAFT, SHIFT FORK AND SLEEVE AT4610 REMOVE SHIFT FORK SHAFT FROM SHIFT FORK Head Plug Shift Fork Remove the head plug, spring and ball. Pull out the shift fork shaft from shift fork.
  • Page 188 TF-28 TRANSFER (A540H) Component Parts (Transfer Lower Valve Body) Transfer Lower Valve Body COMPONENTS No. 2 Low-High Shift Valve Transfer Clutch Modulator Valve Lower Valve Body No. 1 Low-High Shift Valve Retainer Plug AT4425 SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS AND RETAINERS Coil outer diameter Free length Total No.
  • Page 189 TF-29 TRANSFER (A540H) Component Parts (Transfer Lower Valve Body) ASSEMBLY OF TRANSFER VALVE BODY INSTALL PLATE AND NEW GASKETS ON TRANSFER LOWER VALVE BODY Plate Gasket Install a new gasket and plate and then the other new gasket. HINT: Both gaskets are the same. AT4613 INSTALL TRANSFER LOWER VALVE BODY Each bolt length (mm, in.) is indicated in the figure.
  • Page 190 TF-30 TRANSFER (A540H) Component Parts (Transfer Lower Valve Body) Install transfer shift lever. HINT: Engage shift fork and transfer shift lever. Shift Install and tighten the lock bolts. Shift Fork Torque: 40 kg-cm (35 in.-lb, 3.9 N-m) Lever Lock Bolt AT4615 INSTALL TRANSFER VALVE BODY ASSEMBLY Install the new transfer case gaskets and valve...
  • Page 191 TF-31 TRANSFER (A540H) Assembly of Component Parts ASSEMBLY OF COMPONENT PARTS INSTALL CASE SIDE Install the plate washer. HINT: First install a washer of the same thickness as before. AT4521 Using SST and a press, press in the outer race. 09316-60010 (09316-00010, 09316-00060) AT4522 INSTALL RIGHT CASE SIDE...
  • Page 192 TF-32 TRANSFER (A540H) Assembly of Component Parts Install the driven pinion bearing cage. Torque: 400 kg-cm (29 ft-lb, 39 N-m) HINT: Do not install the O-ring. AT4491 Install the ring gear mounting case and center differential case. Using a dial indicator, measure the ring gear back- lash.
  • Page 193 TF-33 TRANSFER (A540H) Assembly of Component Parts ADJUST TOTAL PRELOAD Install the transfer right case. 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. AT4524 Using SST and a spring tension gauge, measure the total preload.
  • Page 194 TF-34 TRANSFER (A540H) Assembly of Component Parts Heel Contact Face Contact Proper Contact Select an adjusting shim that will bring the driven pinion closer to the ring gear. Toe Contact Flank Contact Select an adjusting shim that will shift the driven pinion away from the ring gear.
  • Page 195 TF-35 TRANSFER (A540H) Assembly of Component Parts REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY Remove the six bolts and driven pinion bearing cage assembly. AT4491 REMOVE DIFFERENTIAL LEFT SIDE BEARING OUTER RACE AND PLATE WASHER Using SST, remove the outer race and plate washer. 09308-00010 AT4510 INSTALL OIL SEAL...
  • Page 196 TF-36 TRANSFER (A540H) Assembly of Component Parts INSTALL DRIVEN PINION BEARING CAGE ASSEMBLY Coat the O-ring with gear oil, and install it to the bearing cage assembly. Install the bearing cage with adjust shim (Previously selected) to the transfer left case. Install and torque the six bolts.
  • Page 197 TF-37 TRANSFER (A540H) Assembly of Component Parts Install the right case to the left case. 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. CHECK TOTAL PRELOAD (See page AT-126) AT4524 INSTALL ADJUSTING NUT LOCK PLATE...
  • Page 198 TF-38 TRANSFER (A540H) Assembly of Component Parts Install the right case retainer to the transfer right case. Install and torque the five bolts. Torque: 300 kg-cm (22 ft-lb, 29 N-m) AT4333 INSTALL EXTENSION HOUSING Using SST and a hammer, drive in a new oil seal as shown.
  • Page 199 TF-39 TRANSFER (A540H) Assembly of Component Parts INSTALL TRANSFER MODE SELECT LEVER AND ROD Install the lever, rod and lever guide. Install and torque the two bolts. 55 kg-cm (48 in.-lb, 5.4 N-m) Torque: 115 kg-cm (8 ft-lb, 11 N-m) AT4309 Install the bolt while setting the lever as shown.

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