TOYOTA CAMRY 1999 Service Repair Manual

AUTOMATIC TRANSAXLEDIFFERENTIAL ASSEMBLY ±
AX±95
DIFFERENTIAL ASSEMBLY
COMPONENTS
AX04D±02

AUTOMATIC TRANSAXLEDIFFERENTIAL ASSEMBLY ±
AX±96
DIFFERENTIAL CASE DISASSEMBLY
1. REMOVE SIDE BEARING
Using SST, remove the 2 side bearings.
SST 09608±16011, 09550±40010
2. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 12 bolts.
(c) Using a plastic hammer, tap out the ring gear.
3. CHECK SIDE GEAR BACKLASH
Using a dial gauge, measure the backlash of each side
gear while holding one pinion toward the case.
Standard backlash:
0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
AX0TZ±02

AUTOMATIC TRANSAXLEDIFFERENTIAL ASSEMBLY ±
AX±97
4. DISASSEMBLE DIFFERENTIAL CASE
(a) Drive out the pinion shaft lock pin from the side on which
the ring gear is installed.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinions and side gears with the 4 thrust
washers.
DIFFERENTIAL CASE ASSEMBLY
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the removed thrust washers to the side gears.
(b) Install the side gears with thrust washers, pinion thrust
washers and pinion gears.
(c) Install the pinion shaft.
AX0U0±02

AUTOMATIC TRANSAXLEDIFFERENTIAL ASSEMBLY ±
AX±98
(d) Check the side gear backlash.
Measure the side gear backlash while holding one pinion
gear toward the case.
Standard backlash:
0.05±0.20 mm (0.0020±0.0079 in.)
Refering to the table below, select thrust washers which
will ensure that the backlash is within specification. Try to
select washers of the same size for both sides.
Thrust washer thickness
mm (in.)
Thickness mm (in.)Thickness mm (in.)
1.60 (0.0630)1.70 (0.0670)
1.80 (0.0709)
If the backlash is not within specification, install a thrust
washer of a different thickness.
(e) Using a pin punch and hammer, drive the lock pin through
the case and hole in the pinion shaft.
(f) Stake the differential case.
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear to about 100°C (212°F) in an oil bath.
NOTICE: Do not heat the ring gear above 110°C (230°F).
(c) Carefully remove the ring gear from the oil bath.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
Install the 12 bolts.
HINT: Align the matchmarks on the differential left case
and contact the ring gear.
(f) Tighten the set bolts uniformly a little at a time.
Torque the bolts.
Torque: 124 N´m (1,260 kgf´cm, 91 ft´lbf)

AUTOMATIC TRANSAXLEDIFFERENTIAL ASSEMBLY ±
AX±99
3. INSTALL SIDE BEARING
(a) Install the speedometer drive gear onto the differential
case.
(b) Using SST and a press, press in the RH side bearing onto
the differential case.
SST 09316±20011
(c) Using SST and a press, press in the LH side bearing onto
the differential case.
SST 09316±60010 (09316±00010)

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±100
COMPONENT PARTS INSTALLATION
Disassembly, inspection and assembly of each component group have been indicated in the preceding
chapter. Before assembly, make sure, again, that all component groups are assembled correctly.
If something wrong is found in a certain component group during assembly, inspect and repair this group
immediately.
Recommended ATF: D±@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2])
GENERAL INSTALLATION NOTES:
(a) The automatic transaxle is composed of highly precision±finished parts, necessitating careful inspec-
tion before assembly because even a small nick could cause fluid leakage or affect performance.
(b) Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes.
(c) Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
(d) Use petroleum jelly to keep small parts in their places.
(e) Do not use adhesive cements on gaskets and similar parts.
(f) When assembling the transaxle, be sure to use new gaskets and O±rings.
(g) Dry all parts with compressed air±never use shop rags.
(h) Be sure to install the thrust bearings and races in the correct direction and position.
AX04G±06
AX04H±03

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±101
MarkThrust Bearing Outside Diameter
mm (in.)Thrust Bearing Inside Diameter
mm (in.)
ASee page AX±11827.7 (1.091)
B47.6 (1.874)31.4 (1.236)
C45.5 (1.791)30.1 (1.185)
D45.5 (1.791)30.1 (1.185)
E38.7 (1.524)22.6 (0.890)
F46.3 (1.823)28.6 (1.126)

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±102
DIFFERENTIAL AND DRIVE PINION
INSTALLATION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
(a) Using SST, install the bearing to the drive pinion shaft.
SST 09350±32014 (09351±32120)
(b) Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with the
pinion shaft.
(c) Using a brass bar and hammer, slightly tap the bearing
cage into the transaxle case until the snap ring groove in
the bore can be seen.
(d) Using SST, install snap ring into the bore.
SST 09350±32014 (09351±32050)
(e) Using SST, install the snap ring.
SST 09350±32014 (09351±32050)
AX0U1±02

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±103
2. PLACE OIL SLINGER AND NEW SPACER
HINT: Install the spacer with the small end downward.
3. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350±32014 (09351±32100, 09351±32140)
4. INSTALL COUNTER DRIVE GEAR
(a) Place a brass bar into the transaxle hole to hold the drive
pinion shaft.
(b) Using SST, press in the counter driven gear until the
counter driven gaer bearing almost touches the counter
gear.
SST 09350±32014 (09351±32140)
5. INSTALL NEW LOCK NUT AND ADJUST DRIVE PIN-
ION PRELOAD
(a) Install the new lock nut.
(b) Using SST to hold the gear, tighten the nut.
Torque: 280 N´m (2,855 kgf´cm, 206 ft´lbf)
SST 09330±00021, 09350±32014 (09351±32032)
(c) Turn the gear counterclockwise and clockwise several
times.
(d) Using a small torque wrench, measure the preload of the
drive pinion.
Drive pinion preload (at starting):
New bearing
1.0±1.6 N´m (10±16 kgf´cm, 8.7±13.9 in.´lbf)
Reused bearing
0.5±0.8 N´m (5±8 kgf´cm, 4.3±6.9 in.´lbf)

If the preload is greater than specified, replace the
bearing spacer.

AUTOMATIC TRANSAXLECOMPONENT PARTS INSTALLATION ±
AX±104

If the preload is less then specified, retighten the nut
13 N´m (130 kgf´cm, 9 ft´lbf) at a time until the speci-
fied preload is reached.
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 353 N´m (3,600 kgf´cm, 260 ft´lbf)
(e) If the preload is adjusted within specification, make a note
of it.
(f) Stroke the lock nut.
6. INSTALL APPLY GASKET
7. PLACE OUTER RACE AND SHIM ONTO RH SIDE
BEARING
8. PLACE DIFFERENTIAL CASE INTO TRANSAXLE
CASE
Be sure to install the shim and outer race into place.