clutch TOYOTA CAMRY 1999 Service Repair Manual

SS09N±01
SS±52
± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (S51)
215 Author: Date:
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head6465047Transaxle x Engine 17 mm head
14 mm head
64
46
650
470
47
34
Cruise control actuator x Body (w/ Cruise control)131309
Starter x Transaxle3737828
Clutch release cylinder x Transaxle121209
Clutch line bracket x Transaxle Bolt A121209Clutch line bracket x Transaxle Bolt A
(See page MX±4) Bolt B
12
6.9
120
70
9
61 in.´lbf
Manifold stay Front side4242531
Manifold stay Rear side3940029
Front wheel1031,05076
Exhaust pipe bracket Bolt1919514Exhaust ie bracket Bolt
Nut
19
33
195
330
14
24
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe5657041
No.1 exhaust pipe support bracket x Front suspension member3333024
Stabilizer bar link x Stabilizer bar3940029
Stabilizer bar bracket x Front suspension member1919514
PS gear assembly x Front suspension member1811,850134
Front engine mounting insulator x Front suspension member Silver bolt4445033Front engine mounting insulator x Front sus ension member Silver bolt
Green bolt
44
66
450
670
33
48
LH engine mounting insulator x Front suspension member8082059
LH engine mounting bracket x Transaxle6465047
Rear engine mounting insulator x Front suspension member6667048
Steering return pipe x Front suspension member101007
Front suspension member with lower suspension arm Bolt A1811,850134Front sus ension member with lower sus ension arm Bolt A
Bolt B
181
32
1,850
330
134
24Bolt B
(See page MX±4) Nut C
32
36
330
370
24
27
LH stiffener plate3738027
RH stiffener plate3940029
Rear end plate9.39582 in.´lbf
Shift cable grommet retainer x Body4.95043 in.´lbf
Shift lever assembly x Body121209
Transmission case x Transaxle case2930022
Transmission case x Case cover2930022
Transmission case protector1818513
Rear bearing retainer4243031
Output shaft front bearing lock plate1818513
Transaxle case receiver set bolt7.47565 in.´lbf
5th driven gear lock nut1231,25090
Reverse idler shaft lock bolt2930022
Control shaft cover3737527
Control shift lever x Lever shaft6.46556 in.´lbf
Ring gear x Differential case8385061
Selecting bellcrank x Transmission case3738027

± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (S51)
SS±53
216 Author: Date:
Engine mount bracket x Transaxle5253038
Reverse shift arm bracket1818513
No.3 shift fork x Shift fork shaft1818513
Lock ball assembly2930022
Filler and Drain plugs4950036
Back±up light switch4445033
Differential side bearing retainer1818513
Release bearing retainer7.47565 in.´lbf
Straight screw plug131309
Vehicle speed sensor driven gear5.45548 in.´lbf
Clutch release fork support3940029

SS0AT±01
± SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A140E)
SS±55
218 Author: Date:
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Starter4243031
Transaxle x Rear end plate2525018
Transaxle x No.1 exhaust pipe support bracket1919514
Transaxle x Engine6667048
Torque converter clutch x Drive plate2728020
Body x Front lower brace Bolt
Nut181
361,850
370134
27
Body x Rear lower brace 19 mm head bolt
14 mm head bolt
Nut181
32
361,850
330
370134
24
27
Front suspension member x FR engine mounting TMC made
TMMK made: Green color bolt
TMMK made: Silver color bolt80
66
44820
670
45059
48
32
Front suspension member x RR engine mounting6667048
Front suspension member x LH engine mounting8082059
Transaxle x LH engine mounting6465047
Front suspension member x Steering return pipe mounting bracket101007
Front suspension member x Stabilizer bar bracket1919514
Stabilizer bar x Stabilizer bar link3940029
Ball joint x Lower suspension arm1271,30094
Steering gear housing set bolt x Nut1811,850134
Exhaust manifold x Front exhaust pipe6263046
Front suspension member x Exhaust pipe No.1 support bracket3333024
Front exhaust pipe x Center exhaust pipe5657041
No.1 exhaust pipe support bracket x Exhaust pipe clamp3333024
Axle hub nut2943,000217
Steering knuckle x Tie rod end4950036
Vehicle speed sensor x Transaxle1616012
Park/neutral position switch x Transaxle Bolt
Nut5.4
6.955
7048 in.´lbf
61 in.´lbf
Park/neutral position switch x Control shaft lever131309
Control shaft lever x Control cable1515011
Oil pan x Drain plug4950036
Oil pan x Transaxle4.95043 in.´lbf
Valve body x Manual valve body101007
Valve body x Transaxle101007
Drive shaft center bearing lock bolt3233024
Stiffener plate Front side
Rear side42
39430
40031
29
Exhaust manifold stay Front side
Rear side42
39430
40031
29

SS0BL±01
SS±56
± SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A541E)
219 Author: Date:
AUTOMATIC TRANSAXLE (A541E)
SERVICE DATA
Line pressure (wheel locked)Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
401 ± 461 kPa (4.1 ± 4.7 kgf/cm2, 58 ± 66 psi)
804 ± 882 kPa (8.2 ± 9.0 kgf/cm2, 117 ± 128 psi)
1,138 ± 1,236 kPa (11.6 ± 12.6 kgf/cm
2, 165 ± 179 psi)
1,716 ± 1,854 kPa (17.5 ± 18.9 kgf/cm2, 249 ± 269 psi)
Engine stall revolution2,600 ± 150 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF)
N position
700 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)Between boot and face and inner cable stopper
0 ± 1 mm (0 ± 0.04 in.)
Drive plate runoutMax.
Torque converter clutch runout Max.
Torque converter clutch installation distance0.3 mm (0.0118 in.)
0.20 mm (0.0079 in.)
More than 13.7 mm (0.539 in.)
Lock±up point (Throttle valve opening 5%)
3rd gear (O/D main switch OFF) Lock±up ON
Lock±up OFF
O/D gear Lock±up ON
Lock±up OFF
60 ± 65 km/h (37 ± 40 mph)
53 ± 58 km/h (33 ± 36 mph)
60 ± 64 km/h (37 ± 40 mph)
53 ± 58 km/h (33 ± 36 mph)
Shift schedule
D position
(Throttle valve fully opened) 1 "2
2 "3
3 "O/D
O/D "3
3 "2
2 "1
(Throttle valve fully closed) 3 "O/D
O/D "3
2 position
(Throttle valve fully opened) 1 "2
3 "2
2 "1
L position
(Throttle valve fully opened) 3 "2
2 "1
60 ± 66 km/h (37 ± 41 mph)
112 ± 121 km/h (70 ± 75 mph)
174 ± 183 km/h (108 ± 114 mph)
167 ± 176 km/h (104 ± 109 mph)
104 ± 112 km/h (65 ± 70 mph)
50 ± 55 km/h (31 ± 34 mph)
35 ± 40 km/h (22 ± 25 mph)
20 ± 25 km/h (12 ± 16 mph)
60 ± 66 km/h (37 ± 41 mph)
122 ± 130 km/h (76 ± 81 mph)
50 ± 55 km/h (31 ± 34 mph)
106 ± 115 km/h (66 ± 71 mph)
54 ± 59 km/h (34 ± 37 mph)

SS0BM±01
± SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A541E)
SS±57
220 Author: Date:
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Front engine front mounting insulator x Front frame assemblyTMC:
TMMK:
Green color bolt
Silver color bolt80

66
44820

670
45059

48
32
Rear engine mounting insulator x Front frame assembly8082059
LH transaxle mounting insulator x Transaxle6465047
Engine mounting absorber x Front frame assembly4849035
Transaxle x Engine 17 mm bolt6667048
Transaxle x Engine 12 mm bolt4849035
Torque converter clutch x Drive plate4142030
Valve body x Transaxle case1111 08
Oil strainer x Valve body1111 08
Oil pan x Transaxle case7.88069 in.´lbf
Oil pan drain plug4950036
Park/Neutral position switch x Transaxle case (bolt)5.45548 in.´lbf
Park/Neutral position switch (nut)6.97061 in.´lbf
B3 apply pipe retainer1111 08
Connector clamp1111 08
Manual valve body x Transaxle case1111 08
Detent spring x Manual valve body1111 08
Oil pipe bracket101007
Steering gear housing x Front suspension member1811,850134
Stabilizer bar bracket1919514
Vehicle speed sensor x Transaxle case4.95043 in.´lbf
Direct clutch speed sensor x Transaxle case1111 08
Transfer lubrication apply pipe retainer1111 08
Exhaust manifold bracket x Transaxle case Except California
California20
34200
35014
25
Exhaust manifold plate Except California
California20
34200
35014
25
Front frame x Body 19 mm1811,850134
Front frame x Body 14 mm3233024
Front frame x Body Nut3637027
Exhaust front pipe x Exhaust center pipe5657041
Exhaust manifold x Exhaust front pipe6263046
Exhaust front pipe support stay x Exhaust front pipe support bracket3333024
Exhaust pipe support x Front frame3333024
Starter x Torque converter clutch housing3940029
Transaxle control shaft lever x Park/neutral position switch1515011
Throttle cable adjusting nut1515011
Drive plate x Crankshaft8385061
Shift control cable x Transaxle control shaft lever1515011
Throttle cable retaining plate set bolt5.45548 in.´lbf
Shift solenoid valve No.1, No.2, SL, SLN x Valve body6.66758 in.´lbf

SS05V±02
± SERVICE SPECIFICATIONSAIR CONDITIONING
SS±71
234 Author: Date:
AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume800 ± 50 g (28.22 ± 1.76 oz.)
Drive belt tension±
New belt165 ± 26 lbf
Used belt110 ± 11 lbf
Idle±up speed±
Magnetic clutch not engaged700 ± 50 rpm
Magnetic clutch engaged700 ± 50 rpm
Magnetic clutch clearance0.5 ± 0.15 mm (0.020 ± 0.0059 in.)

B01154

Snap Ring
Starter Housing
Starter Clutch
Compression Spring
Clutch Shaft
Starter Housing and
Clutch Assembly
Idler Gear
Bearing Stop Collar
Pinion Gear
Compression Spring
Spring Retainer
Steel Ball
Return
Spring

Front Bearing
Armature

O±Ring
Field Frame
(Field Coil)
End Cover Brush Holder
Rear Bearing

Dust Protector

Non±reusable part
Magnetic Switch
Assembly

O±Ring
± STARTING (5S±FE)STARTER
ST±3
1710 Author: Date:

ST03K±01
B01156
B01157
Protrusion
Identation
B01158
B01160
(1)
(4)
(3)
(2)
B01159
ST±6
± STARTING (5S±FE)STARTER
1713 Author: Date:
DISASSEMBLY
1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(c) Pull out the field frame together with the armature.
HINT:
Align the protrusion of the field frame with the identation of the
magnetic switch.
(d) Remove the O±ring from the field frame.
HINT:
At the time of installation, please refer to following items. Use
a new O±ring.
3. REMOVE STARTER HOUSING, CLUTCH
ASSEMBLY AND GEAR
(a) Remove the 2 screws.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove these parts from the magnetic switch:
(1) Starter housing and clutch assembly
(2) Return spring
(3) Idler gear
(4) Bearing
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.

P13481
No Continuity Ohmmeter
B01162
Lock
Free
B01163
Ohmmeter
Terminal 50Terminal C
Continuity
B01164
Ohmmeter
Terminal 50Continuity
ST±10
± STARTING (5S±FE)STARTER
1717 Author: Date:
6. INSPECT BRUSH HOLDER
Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
7. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the pinion gear, idler gear and
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the ring gear of the flywheel/drive plate
for wear or damage.
(b) Check the clutch pinion gear.
Hold the starter clutch and rotate the pinion gear counter-
clockwise, and check that it turns freely. Try to rotate the
pinion gear clockwise and check that it locks.
If necessary, replace the clutch assembly.
8. INSPECT MAGNETIC SWITCH
(a) Check the pull±in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.
(b) Check the hold±in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
9. INSPECT BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
(See page ST±11)

ST03M±03
B01224
B01225
B01226
B01227
Stop Collar
Pinion Gear
Compression
Spring
B01228
± STARTING (5S±FE)STARTER
ST±11
1718 Author: Date:
REPLACEMENT
1. REPLACE CLUTCH ASSEMBLY
(a) Disassemble the starter housing and the clutch assembly.
(1) Mount a brass bar in a vise, and install the starter
housing and clutch assembly to the brass bar.
(2) Push down the pinion gear.
(3) Using a plastic±faced hammer, tap down the stop
collar.
(4) Using a screwdriver, pry out the snap ring.
(5) Remove these parts:

Stop collar

Pinion gear

Compression spring
(6) Push down the starter housing, and remove the
spring retainer.
(7) Disassemble these parts:

Starter housing

Starter clutch

Compression spring

Clutch shaft