TOYOTA CAMRY V20 1986 Service Information

MarkThickness mm (in.)
MarkThickness mm (in.)
A
B
C
D
E1.00 (0.0394)
1.05 (0.0413)
1.10 (0.0433)
1.15 (0.0453)
1.20 (0.0472)F
G
H
J1.25 (0.0492)
1.30 (0.0512)
1.35 (0.0531)
1.40 (0.0551)
AT7788
AT7795
AT7787 AT7794
(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
differential 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.
(d) Using snap ring pliers, install the shaft snap ring.
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.
(b) Install the center differential case.
- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)TF-21

AT7783Matchmarks
AT7796
Conical Spring
Washer Thickness
AT7797
Mark Thickness mm (in.)Mark Thickness mm (in.)
A
B
C
D
E
F1.00 (0.0394)
1.05 (0.0413)
1.10 (0.0433)
1.15 (0.0453)
1.20 (0.0472)
1.25 (0.0492)G
H
J
K
L1.30 (0.0512)
1.35 (0.0531)
1.40 (0.0551)
1.45 (0.0571)
1.50 (0.0591)
AT7786
1.05
(0.0413) 1.00
(0.0394) 0.95
(0.0374)
Conical spring washer thickness
mm
(in.)
(h) Referring to the table below, select the thrust washer
which will ensure that the backlash is within specifi-
cation. Try to select a washer of the same size.
Standard clearance
(c) Install the thrust washer.
(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-lb, 97 N-m)
HINT: Do not install the O-ring.
(f) Using a caliper, measure the conical spring washer
thickness.
(g) Using a dial indicator, measure the thrust clearance
of center differential case while holding the ring
gear mounting case.
Standard clearance:
Thrust clearance
mm
(in.)
0.60
(0.0236)
0.50
(0.0197)
0.40
(0.0157)
0.30
(0.0118)
0.20
(0.0079)
0.10
(0.0039)
AT3460
(i) Remove ring gear mounting right case.
TF-22- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)

AT7787
AT7786
AT7783
Matchmarks
AT7799 AT7798
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.
7. INSTALL CENTER DIFFERENTIAL CASE
8. INSTALL THRUST WASHER (Previously selected)
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-lb, 97 N-m)
NOTICE: Using the soft jaws, hold the left case in a vise.
10. INSTALL OIL PUMP DRIVE GEAR
(a) Install the oil pump drive gear.
- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)TF-23

AT7800
(b) Install the shaft snap ring.
TF-24- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)

AT4605
r Non-reusable part

Precoated part: Specified torque
kg-cm (ft-lb, N-m)Differential Lock
Shift Fork ShaftTransfer Left Case Differential Lock
Shift Forkr Oil Seal Ball Spring
120 (9, 12)
Head PlugTransfer Shift Lever Valve Body StrainerDifferential Lock Sleeve Transfer Valve Body
Gasket r Transfer Case GasketTransfer Valve Body Assemblyr O-ring
110 (8, 11)Center Differential Control Solenoidr O-ring
70 (61 in.-lb, 6.9) 145 (10, 14)
Transfer Left Case
COMPONENTS
- TRANSFER (A540H)Component Parts (Transfer Left Case)TF-25

AT4520
O-ringO-ring
AT4606
AT4607
GasketStrainer
AT4608
Shift Lever
AT4519
DISASSEMBLY OF TRANSFER LEFT CASE
1. REMOVE CENTER DIFFERENTIAL CONTROL
SOLENOIDS
(a) Remove the four bolts and solenoid.
(b) Remove the four O-rings from the solenoids.
2. REMOVE TRANSFER VALVE BODY ASSEMBLY
(a) Remove the eight bolts and transfer valve body
assembly.
(b) Remove the transfer valve body gasket.
(c) Remove transfer case gaskets and valve body
strainer.
3. REMOVE TRANSFER SHIFT LEVER
(a) Remove the lock bolt and transfer shift lever.
TF-26- TRANSFER (A540H)Component Parts (Transfer Left Case)

AT4609
AT4610
AT4612
AT4613
GasketPlate
AT4611
Shift Fork Shaft Shift ForkHead Plug
(b) Using a screwdriver, remove the oil seal.
4. REMOVE SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
5. REMOVE SHIFT FORK SHAFT FROM SHIFT FORK
(a) Remove the head plug, spring and ball.
(b) Pull out the shift fork shaft from shift fork.
DISASSEMBLY OF TRANSFER VALVE BODY
REMOVE TRANSFER LOWER VALVE BODY
(a) Remove the eight bolts and transfer lower valve
body.
(b) Remove the two gaskets and plate from the
transfer upper valve body.
- TRANSFER (A540H)Component Parts (Transfer Left Case)TF-27

SpringFree length
mm (in.)Coil outer diameter
mm (in.)Total No. of Coils
Color
Transfer clutch modulator valve 32.3 (1.272) 7.6 (0.299) 16None
No. 2 Low-high shift valve
28.9 (1.138) 7.0 (0.276) 14None
No. 1 Low-high shift valve
RetainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
6.5
(0.256)5.0
(0.197)3.2
(0.126) No. 2 Low-high shift valve
No. 1 Low-high shift valve
AT4425
PlugRetainerNo. 1 Low-High
Shift ValveLower Valve Body Transfer Clutch
Modulator ValveNo. 2 Low-High
Shift Valve
Transfer Lower Valve Body
COMPONENTS
SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS AND RETAINERS
HINT: During reassembly please refer to the spring specifications above to help discriminate between the
different springs.
TF-28- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)

AT4612
AT4964
Shift Fork ShaftShift Fork
AT4610
AT4614 AT4613
GasketPlate
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 lower valve body into place.
(b) 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-lb, 25 N-m)
2. INSTALL SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
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
hammer, drive in the oil seal as shown.
- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)TF-29

AT4607
Strainer
Gasket
AT4606
AT4520
O-ringO-ring
AT4519 AT4615
Lock BoltShift
Lever Shift
Fork
(c) Install transfer shift lever.
HINT: Engage shift fork and transfer shift lever.
(d) Install and tighten the lock bolts.
Torque: 40 kg-cm (35 in.-lb, 3.9 N-m)
4. INSTALL TRANSFER VALVE BODY ASSEMBLY
(a) Install the new transfer case gaskets and valve
body strainer.
(b) Install the new transfer valve body gasket.
(c) Install the transfer valve body assembly.
(d) Tighten the bolts.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
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 the solenoids.
Torque: 145 kg-cm (10 ft-lb, 14 N-m)
TF-30- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)