brake TOYOTA CAMRY V20 1986 Service Information

ABBREVIATIONS USED IN THIS MANUAL
A/T ATM Automatic Transmission
ATF Automatic Transmission Fluid
B
0 Overdrive Brake
B
1 Second Coast Brake
B
2 Second Brake
B
3 First and Reverse Brake
C
0 Overdrive Clutch
C
1 Forward Clutch
C
2 Direct Clutch
D Disc
D/F Differential
LH Left
MP Multipurpose
O/D Overdrive
P Plate
RH Right
SSM Special Service Materials
SST Special Service Tools
IN-6- INTRODUCTIONAbbreviations Used in This Manual

Illustration
Part No. Part Name
Note
09031 - 00030
Pin Punch
Part Name
Note
Feeler gauge
Check major clearance.
Vernier caliper with depth gauge
Check length of second coast brake piston rod.
Dial indicator with magnetic base
Check piston stroke and end play of the output shaft.
Dial indicator Check inside diameter of major bushing.
Straight edge Check side clearance of oil pump.
Torque wrenchPart Name Part No. Use etc.
Seal packing 1281,
Three bond 1281 or equivalent08826 - 00090Transfer right case y Transfer left case (A540H)
Transfer inspection hole cover (A540H)
Transfer case y Differential carrier cover
Differential LH bearing retainer (A540E, A540H)
Differential RH retainer (A540E)
Transaxle y Transfer assembly (A540H)
Adhesive 1324,
Three bond 1324 or equivalent08833 - 00070Differential LH bearing retainer set bolt
Differential carrier cover set bolt
Torque converter mounting bolt
Differential RH retainer set bolt (A540E)
Transfer set bolt (A540H)
SSM (SPECIAL SERVICE MATERIALS)
RECOMMENDED TOOL
EQUIPMENT
AT-12- AUTOMATIC TRANSAXLEPreparation

Second
coast brakePiston stroke
Piston rod length2.0 - 3.5 mm
95.2 mm
96.3 mm0.079 - 0.138 in.
3.748 in.
3.791 in.
Oil pump
STD
Maximum
STD
Maximum
STD
Maximum
Maximum
Maximum
Maximum Body clearance
Tip clearance
Side clearance
Pump body bushing inside diameter
Stator shaft bushing inside diameter
Front side
Rear side0.07 - 0.15 mm
0.3 mm
0.11 - 0.14 mm
0.3 mm
0.02 - 0.05 mm
0.1 mm
38.18 mm
21.57 mm
27.07 mm0.0028 - 0.0059 in.
0.012 in.
0.0043 - 0.0055 in.
0.012 in.
0.0008 - 0.0020 in.
0.004 in.
1.5031 in.
0.8492 in.
1.0657 in.
Direct clutch
Maximum Piston stroke
Drum bushing inside diameter
Flange thickness0.0358 - 0.0531 in.
1.9004 in.
0.1063 in.
0.1181 in. 0.91 - 1.35 mm
48.27 mm
2.70 mm
3.00 mm
Forward
clutchPiston stroke
Flange thickness1.41 - 1.82 mm
3.00 mm
3.37 mm0.0555 - 0.0717 in.
0.1181 in.
0.1327 in.
Front
planetary
gearMaximum
Maximum
STD
Maximum Sun gear bushing inside diameter
Ring gear flange bushing inside diameter
Planetary pinion gear thrust clearance22.59 mm
30.08 mm
0.16 - 0.56 mm
0.61 mm0.8894 in.
1.1842 in.
0.0063 - 0.0220 in.
0.024 in.
Rear
planetary
gearPlanetary pinion gear thrust clearance
STD
Maximum0.16 - 0.56 mm
0.61 mm0.0063 - 0.0220 in.
0.024 in.
First and
reverse brakePack clearance0.85 - 2.05 mm0.033 - 0.081 in.
Overdrive
unitDirect clutch piston stroke
Direct clutch bushing inside diameter
Counter drive gear preload
Planetary pinion gear thrust clearanceMaximum
at Starting
STD
Maximum0.0689 - 0.0980 in.
0.8713 in.
940 - 1,560 g 2.1 - 3.4 lb 9.2 - 15.3 N1.75 - 2.49 mm
22.13 mm
0.0063 - 0.0220 in.
0.024 in. 0.16 - 0.56 mm
0.61 mm
AUTOMATIC TRANSAXLE (A540E)
Specifications
A-2- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Second
coast brakeSame the A540E automatic transaxle (See page A-2)
Oil pump=
Direct clutch Piston stroke
Drum bushing inside diameter Maximum
Flange thickness1.11 - 1.47 mm
48.27 mm
2.70 mm
3.00 mm0.0437 - 0.0579 in.
1.9004 in.
0.1063 in.
0.1181 in.
Forward
clutchSame the A540E automatic transaxle (See page A-2)
Front
planetary gear=
Rear
planetary gear=
First and
reverse brakePack clearance 0.0409 - 0.0850 in.1.04 - 2.16 mm
Over drive
unitSame the A540E automatic transaxle (See page A-2)
Valve body
springSame the A540E automatic transaxle (See page A-3)
Valve body
retainerSame the A540E automatic transaxle (See page A-3)
Accumulator
springSame the A540E automatic transaxle (See page A-4) Part tightenedkg-cmft-lbN-m
Oil cooler pipe union
Oil pan
Valve body y Transaxle case
Accumulator y Cover
Oil pump y Transaxle case
O/D case y Transaxle case
Differential LH side bearing retainer
Differential RH retainer
Differential carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Differential left case y Right case
Ring gear y Differential case275
50
11 0
100
225
250
195
195
400
100
67
640
1,26027
4.9
11
10
22
25
19
19
39
10
6.6
63
124 20
43 in.-lb
8
7
16
18
14
14
29
7
58 in.-lb
46
91
Torque Specifications
AUTOMATIC TRANSAXLE (A540H)
Specifications
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-5

Type of Transmission
A540E
A540H
Type of Engine
2VZ-FE
3S-FE
Torque ConverterStall Torque Ratio
1.9 : 1
2.0 : 1
Lock-Up Mechanism
Equipped
u
Gear Ratio1st Gear
2.810
u
2nd Gear
1.549
u
3rd Gear
1.000
u
O/D Gear
0.734
u
Reverse Gear
2.296
Number of Discs and
Plates (Disc/Plate)C
0O/D Direct Clutch
2/2
u
C
1Forward Clutch 4/4
u
C
2Direct Clutch 3/3
u
B
22nd Brake
3/3
u
B
3First & Reverse Brake 7/7 6/6
B
0O/D Brake
3/3
u
mm (in.)B1 Band Width
38 (1.50)
25 (0.98)
AT FType
ATF DEXRON
IIATF Type T or
equivalent
Capacity liter
(US qts, Imp. qts)A/T5.9 (6.2, 5.2)
7.0 (7.4, 6.2)
D/F1.0 (1.1, 0.9)
Transfer OilTypeTransaxle oil E50,
API GL5,
SAE 75W-90
or equivalent
Capacity liter (US qts, Imp. qts)
0.7 (0.7, 0.6)
General Specification
u
AT-4- AUTOMATIC TRANSAXLEDescription

AT3206
Planetary Gear Unit
Shift lever
positionGear position
C
0C1C2B0B1B2B3F0F1F2
PParking


RReverse






NNeutral


D1st







2nd









3rd










O/D








21st







2nd











*3rd










L1st









*2nd












OPERATION
A540E, A540H

..... Operating
*Down-shift only-no up-shift
Rear Planetary
GearFront Planetary
Gear Intermediate
Shaft O/D Planetary
Gear O/D One-Way
Clutch (F
0)One-W ay Clutch
No. 1 (F1) Counter
Drive GearInput Shaft Forward
Clutch (C
1)Direct
Clutch (C2) One-W ay Clutch
No. 2 (F2) O/D Brake (B0) O/D Direct
Clutch (C
0)First and Reverse
Brake (B3)Second Brake (B2)Second Coast
Brake (B1)
- AUTOMATIC TRANSAXLEOperationAT-5

NOMENCLATURE
OPERATION
Forward Clutch
C
1Connects input shaft and front planetary ring gear
Direct Clutch
C
2Connects input shaft and front & rear planetary sun gear
2nd Coast Brake
B
1Prevents front & rear planetary sun gear from turning either clockwise or counterclockwise
2nd Brake
B
2Prevents outer race of F1 from turning either clockwise or counterclockwise, thus preventing front &
rear planetary sun gear from turning counterclockwise
1st & Reverse Brake
B
3Prevents rear planetary carrier from turning either clockwise or counterclockwise
No. 1 One-Way Clutch
F
1When B2 is operating, prevents front & rear planetary sun gear from turning counterclockwise
No. 2 One-Way Clutch
F
2Prevents rear planetary carrier from turning counterclockwise
O/D Direct Clutch
C
0Connects overdrive sun gear and overdrive-planetary carrier
O/D Brake
B
0Prevents overdrive sun gear from turning either clockwise or counterclockwise
O/D One-Way Clutch
B
0When transmission is being driven by engine, connects overdrive sun gear and overdrive carrier
Planetary GearsThese gears change the route through which driving force is transmitted in accordance with the
operation of each clutch and brake in order to increase or reduce the input and output speed
AT3207
Rear Planetary CarrierFront Planetary Ring Gear OUT O/D Planetary Sun GearINInput Shaft Shaft O/D Planetary CarrierIntermediateFront Planetary Carrier Rear Planetary
Ring Gear O/D Planetary Ring Gear
and Counter Drive Gear
FUNCTION OF COMPONENTS
Front and Rear Planetary Sun Gear
AT-6- AUTOMATIC TRANSAXLEOperation

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