clutch TOYOTA CAMRY V20 1986 Service Information

AT1097
OUTIN
D or 2 Range 1st Gear
AT1102
OUTIN
2 Range 2nd Gear
AT1098
OUTIN
D Range 2nd Gear
AT1103
OUTIN
L Range 1st Gear
AT1099
OUTIN
D Range 3rd Gear
AT1101
OUTIN
R Range Reverse Gear
AT1100
OUTIN
D Range O/D Gear
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.
Shift change is carried out by altering the combination of clutch and brake operation.
Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle
opening angle and vehicle speed, and shift change automatically occurs.
The conditions of operation for each gear position are shown on the following illustrations:
- AUTOMATIC TRANSAXLEOperationAT-7

VALVE BODY
Hydraulic Control System

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.
Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hy-
draulic pressure acting on the torque converter, clutches and brakes in accordance with the vehicle driving
conditions.
There are three solenoid valves on the valve body.
The No. 1 and No. 2 solenoid valves are turned on and off by signals from ECU to operate the shift valves
and change the gear shift position.
The No. 3 solenoid valve is operated by signals from the ECU to engage or disengage the lock-up clutch
of the torque converter.

A540H
There are two center differential control solenoid valves on the transfer.
The solenoid valves are adjusting the center differential control pressure.
HYDRAULIC CONTROL SYSTEM
Hydr. pressure control
OIL PUMP
CLUTCHES & BRAKESFluid passage switchingPlanetary gear unit
Torque converter
Throttle Cable
SOLENOID VALVES
ECU
AT-8- AUTOMATIC TRANSAXLEOperation

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.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the
next component group. If a component group can not be assembled because parts are being or-
dered, be sure to keep all parts of that group in a separate container while proceeding with disas-
sembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: A540E ATF DEXRON
II
A540H ATF Type T or equivalent
Recommended oil for the transfer: Transaxle oil E50, API GL5, SAE 75W-90 or equivalent
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean, with any fluid passages and holes blown
through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent acciden-
tally spraying automatic transaxle fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection,
repairs, and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corre-
sponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle
fluid for at least fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are
installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be re-
placed.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
- AUTOMATIC TRANSAXLEComponent Parts (General Notes)AT-39

kg-cm (ft-lb, N-m)
r Non-reusable part
: Specified torque
Parking Lock Pawl 2nd Coast Brake
Band Guide Snap RingBracket 1st and Reverse
Brake Pistonr Second Brake
Drum Gasket Snap Ringr GasketO/D Brake Drumr Gasket FlangeSnap RingSpringSnap RingO/D Planetary Gear
Springr O-Ring DiscBearing Snap RingRear Planetary
Gear
O/D Case250 (18, 25) 225 (16, 22)2nd Brake
DrumRear Planetary
Ring Gear Flange Plate Bearing
BearingDrum and
Sun Gear Bearing
PinBearingThrust
Washer Oil PumpThrust
WasherSecond Coast
Brake Band r O-RingDirect ClutchNo. 1 One-way
Clutch Thrust WasherFront Planetary
Ring Gear
A540E and A540H
PlateA540E: 7 pieces
A540H: 6 pieces
DiscA540E: 7 pieces
A540H: 6 piecesBearing No. 2 One-way
ClutchThrust
WasherThrust
Washer Forward Clutch
Front Planetary
Gear
COMPONENTS (Cont'd)
AT5020
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-15

AT7700
AT3547
AT3548
Forward ClutchThrust Washer Direct Clutch
AT0121 AT3549
26. REMOVE O-RING FROM OIL PUMP
27. REMOVE DIRECT CLUTCH AND FORWARD
CLUTCH
28. SEPARATE DIRECT CLUTCH AND FORWARD
CLUTCH
(a) Separate the direct clutch and forward clutch.
(b) Remove the thrust washer from direct clutch.
29. REMOVE BEARINGS FROM FORWARD CLUTCH
30. REMOVE SECOND COAST BRAKE BAND
(a) Push the pin with a small screwdriver and remove
it from the bolt hole of the oil pump mounting.
(b) Remove the brake band.
HINT: For the method of inspection, refer to page
AT-41.
AT-24- AUTOMATIC TRANSAXLERemoval of Component Parts

AT3557
AT7701
AT3559
AT3560AT3558
38. REMOVE NO. 1 ONE-WAY CLUTCH
39. REMOVE PLATES, DISCS AND FLANGE
HINT: For the method of inspection, refer to page
AT-62.
40. REMOVE SECOND BRAKE DRUM GASKET
Remove the gasket.
41. REMOVE NO. 2 ONE-WAY CLUTCH AND REAR
PLANETARY GEAR
(a) Remove the snap ring.
(b) Remove the No. 2 one-way clutch and rear
planetary gear.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-27

AT0376
SST
AT0194
SST
AT3571
AT0196 AT4168
(e) Remove the overdrive clutch apply gasket and
overdrive brake apply gasket.
47. REMOVE FIRST AND REVERSE BRAKE PISTON
(a) Remove the piston return spring.

Place SST, and compress the return spring
evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)

Using snap ring pliers, remove the snap ring.

Remove SST.

Remove the return spring from the case.
(b) Apply compressed air into the passage of the case
to remove the piston.
HINT: Hold the piston so it is not slanted and blow with
the gun slightly away from the oil hole.
(c) If the piston does not pop out with compressed
air, use needle-nose pliers to remove it.
AT-30- AUTOMATIC TRANSAXLERemoval of Component Parts

AT7709
SST
AT7710AT3613
r Non-reusable partPlateDiscFlangeSnap Ring Thrust Washer Clutch DrumPistonr O-RingSnap Ring Piston Return
Spring
Direct Clutch
COMPONENTS
DISASSEMBLY OF DIRECT CLUTCH
1. CHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) 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
2,
57 - 114 psi, 392 - 785 kPa) as shown.
SST 09350-32014 (09351-32190)
Piston stroke: A540E 0.91 - 1.35 mm
(0.0358 - 0.0531 in.)
A540H 1.11 - 1.47 mm
(0.0437 - 0.0579 in.)
If the piston stroke is greater than the maximum, inspect
each component.
- AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch)AT-47

AT0163
AT2733
SST
AT3614
AT0165
AT2735
2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES
4. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress
the springs with a shop press.
SST 09350-32014 (09351-32070)
(b) Remove the snap ring with snap ring pliers.
(c) Remove the piston return spring.
5. REMOVE CLUTCH PISTON
(a) Install the direct clutch onto the oil pump.
(b) Apply compressed air to the oil pump to remove
the piston. (If the piston does not come out com-
pletely, use needle-nose pliers to remove it.)
(c) Remove the direct clutch from the oil pump.
(d) Remove the two O-rings from the piston.
AT-48- AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch)

AT7711
Printed
Numbers
AT3231
AT0168
AT3614 AT3615 AT3616
INSPECTION OF DIRECT CLUTCH
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the
piston.
(b) Check that the valve does not leak by applying
low-pressure compressed air.
2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
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.

Before assembling new discs, soak them in ATF
for at least fifteen minutes.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of
the direct clutch bushing.
Maximum inside diameter: 48.27 mm (1.9004 in.)
If the inside diameter is greater than the maximum, re-
place the direct clutch.
ASSEMBLY OF DIRECT CLUTCH
1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH
DRUM
(a) Install new O-rings to the piston. Coat the O-rings
with ATF.
(b) Being careful not to damage the O-rings, press
the piston into the drum with the cup side up.
2. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring onto the
piston.
- AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch)AT-49