TOYOTA CAMRY V20 1986 Service Information

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 ordered,
be sure to
keep all parts of that group in a separate container while proceeding with disassembly, 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 accidentally 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 reas-
sembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding 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 replaced.
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) (A540E and A540H)AT±262

DISASSEMBLY OF SECOND COAST BRAKE
PISTON
1. REMOVE OIL SEAL RING
Remove the oil seal ring from the piston.
2. REMOVE PISTON ROD
(a) Remove the E±ring while pushing the piston with
needle±nose pliers.
COMPONENT PARTS
Second Coast Brake
± AUTOMATIC TRANSAXLEComponent Parts (Second Coast Brake) (A540E and
A540H)AT±263

ASSEMBLY OF SECOND COAST BRAKE
PISTON
1. SELECT PISTON ROD
If the band is OK but piston stroke not within the standard value,
select the piston rod.
Piston stroke: 2.0 ± 3.5 mm (0.079 ± 0.138 in.)
There are two lengths of piston rod.
Piston rod length: 95.2 mm l3.748 in.)
96.3 mm (3.791 in.)
2. INSTALL PISTON ROD
(a) Install the plate washer and inner spring to the piston
rod. INSPECTION OF SECOND COAST BRAKE
COMPONENT
If the lining of the brake band is exfoliated or discol-
ored,
or even part of the printed marks is defaced, replace the
brake band.(b) Remove the inner spring, plate washer and pis-
ton rod.
(b) Install the E±ring while pushing the piston.
± AUTOMATIC TRANSAXLEComponent Parts (Second Coast Brake) (A540E and
A540H)AT±264

3. INSTALL OIL SEAL RING
(a) Apply ATF to the oil seal ring.
(b) Install the oil seal ring to the piston.
NOTICE: Do not spread the ring ends more than
necessary.
± AUTOMATIC TRANSAXLE(Second Coast Brake) (A540E and A540H)AT±265

DISASSEMBLY OF OIL PUMP
1. REMOVE OIL SEAL RINGS
Remove the two oil seal rings from the stator shaft
back side.
2. REMOVE THRUST WASHER FROM STATOR SHAFT
BACK SIDE
Oil Pump
± AUTOMATIC TRANSAXLEComponent Parts (Oil Pump) (A540E and A54CH)AT±266

INSPECTION OF OIL PUMP
1. CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body.
Using a feeler gauge, measure the clearance.
Standard body clearance: 0.07 ± 0.15 mm
(0.0028 ± 0.0059 in.)
Maximum body clearance: 0.3 mm (0.012 in.)
If the body clearance is greater than the maximum,
replace the oil pump body subassembly.
2. CHECK TIP CLEARANCE OF DRIVEN GEAR
Measure between the driven gear teeth and the cres-
cent shaped part of the pump body.
Standard tip clearance: 0.11 ± 0.14 mm
(0.0043 ± 0.0055 in.)
Maximum tip clearance: 0.3 mm (0.012 in.)
If the tip clearance is greater than the maximum, re-
place the oil pump body subassembly.
3. CHECK SIDE CLEARANCE OF BOTH GEARS
Using a steel straightedge and a feeler gauge, mea-
sure the side clearance of both gears.
Standard side clearance: 0.002 ± 0.005 mm
(0.0008 ± 0.0020 in.)
Maximum side clearance: 0.1 mm (0.004 in.) 3. REMOVE STATOR SHAFT
Remove the eleven bolts and stator shaft.
HINT: Keep the gears in assembly order.
4. REMOVE FRONT OIL SEAL
Pry off the oil seal with a screwdriver.
± AUTOMATIC TRANSAXLEComponent Parts (Oil Pump) (A540E and A540H)AT±267

There are three different thicknesses for drive and driven gears.
Drive and driven gear thickness
Mark Thickness
A 9.440 ± 9.456 mm (0.3717 ± 0.3723 in.)
B 9.456 ± 9.474 mm (0.3723 ± 0.3730 in.)
C 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 subassembly.
4. CHECK OIL PUMP BODY BUSHING
Using a dial indicator, measure the inside diameter of the oil
pump body bushing.
Maximum inside diameter: 38.18 mm (1.5031 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body subassembly.
5. CHECK STATOR SHAFT BUSHING
Using a dial indicator, measure the inside diameter stator
shaft bushing.
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the inside diameter is greater than the maximum, replace
the stator shaft.
ASSEMBLY OF OIL PUMP
1. INSTALL FRONT OIL SEAL
Using SST and a hammer, install a new oil seal. The sea
end should be flush with the outer edge of the pump body
SST 09350±32014 (09351±32140)
Z. INSTALL DRIVEN GEAR AND DRIVE GEAR
Make sure the top of the gears are facing upward.
± AUTOMATIC TRANSAXLEComponent Parts toil Pump) (A540E and A540H)AT±268

5. INSTALL OIL SEAL RINGS
Install the two oil seal rings to the stator shaft back
side.
NOTICE: Do not spread the ring ends more than necessary.
HINT: After installing the oil seal rings, check that they
move smoothly. 3. INSTALL STATOR SHAFT TO PUMP BODY
(a) Align the stator shaft with each bolt hole.
(b) Torque the eleven bolts.
Torque: 100 kg±cm (7 ft±lb, 10 N±m)
4. INSTALL THRUST WASHER
(a) Coat the thrust washer with petroleum jelly.
(b) Align the tab of the washer with the hollow of the pump
body.
6. CHECK PUMP DRIVE GEAR ROTATION
Turn the drive gear with two screwdrivers and make
sure it rotates smoothly.
NOTICE: Be careful not to damage the oil seal lip.
± AUTOMATIC TRANSAXLEComponent Parts (Oil Pump) (A540E and A540H)AT±269

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), mea-
sure the direct clutch piston stroke applying and
releasing the compressed air (4 ± 8 kg/cm2, 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.
Direct Clutch
± AUTOMATIC TRANSAXLEComponent Parts (Direct Clutch) (A540E and A540H)AT±270

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 completely,
use needle±nose pliers to remove it.)
(c) Remove the direct clutch from the oil pump. 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. 2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE, DISCS AND PLATES
(d) Remove the two O±rings from the piston.(e) Remove the piston return spring.
± AUTOMATIC TRANSAXLE± Component Parts (Oil Pump) (A540E and A540H)AT±271