TOYOTA CAMRY 1999 Service Repair Manual

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±62
4. REMOVE SNAP RING WITH SCREWDRIVER
5. REMOVE FLANGES, DISCS AND PLATES
6. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress the spring
with a press.
SST 09350±32014 (09351±32070, 09351±32200)
(b) Remove the snap ring.
(c) Remove the piston return spring.
7. REMOVE PISTON FROM CLUTCH DRUM
(a) Install the clutch drum on the case.
(b) Apply compressed air to the pressure apply hole of the
case.
(c) Remove the piston from the clutch drum.
If the piston does not come out completely, use needle±
nose pliers to remove it.
(d) Remove the clutch drum from the case.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±63
8. REMOVE O±RINGS
Remove the 2 O±rings from the piston.
OVERDRIVE DIRECT CLUTCH INSPECTION
1. INSPECT OVERDRIVE DIRECT CLUTCH
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying low±pres-
sure compressed air.
2. INSPECT DISCS, PLATES AND FLANGES
Check if the sliding surfaces of the discs, plates and
flanges are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed numbers are defaced, re-
place all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the
2 direct clutch bushings.
Maximum inside diameter:
22.13 mm (0.8713 in.)
If the inside diameter is greater than the maximum, re-
place the direct clutch drum.
OVERDRIVE DIRECT CLUTCH ASSEMBLY
1. INSTALL CLUTCH PISTON
(a) Install new O±rings to the piston. Coat the O±rings with
AT F.
AX03W±03
AX03X±06

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±64
(b) Press the piston into the drum with the cup side up, being
careful not to damage the O±ring.
2. INSTALL PISTON RETURN SPRING
(a) Install the return spring and seat snap ring in place.
(b) Place SST on the spring retainer, and compress the
spring with a press.
SST 09350±32014 (09351±32070, 09351±32200)
(c) Install the snap ring with a screwdriver. Be sure end gap
of snap ring is aligned with the groove of the clutch drum.
3. INSTALL PLATES, DISCS AND FLANGE
Install in order:
P=Plate D=Disc
P±D±P±D±Flange
4. INSTALL SNAP RING
Be sure end gap of the snap ring is not aligned with the
groove of the clutch drum.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±65
5. INSTALL BEARING AND RACE
(a) Coat the bearing with petroleum jelly and install it facing
the race side downward to the clutch drum.
Bearing outer diameter: 46.3 mm (1.823 in.)
Bearing inner diameter: 26.2 mm (1.031 in.)
(b) Coat the race with petroleum jelly and install it to the case.
Race outer diameter: 43.0 mm (1.693 in.)
Race inner diameter: 24.5 mm (0.965 in.)
6. INSTALL DIRECT CLUTCH ON CASE
7. RECHECK PISTON STROKE OF DIRECT CLUTCH
Install a dial indicator and measuring terminal (SST) to-
gether, measure the piston stroke while applying and re-
leasing compressed air (392±785 kPa, 4±8 kgf/cm
2,
57±114 psi).
Piston stroke:
1.75±2.49 mm (0.0689±0.0980 in.)
SST 09350±32014 (09351±32190)
COUNTER DRIVE GEAR DISASSEMBLY
1. CHECK OPERATION OF ONE±WAY CLUTCH
(a) Install the O/D direct clutch into the one±way clutch.
(b) Hold the O/D direct clutch and turn the intermediate shaft.
The shaft should turn freely clockwise and should lock
counterclockwise.
(c) Remove the O/D direct clutch.
AX03Y±03

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±66
2. CHECK COUNTER DRIVE GEAR PRELOAD
(a) Hold the O/D planetary gear in a vise with soft jaws.
HINT: Do not let the counter drive gear touch the vise.
(b) Using a tension gauge, measure the preload.
Preload (at starting):
9.2±15.3 N (940±1,560 g, 2.1±3.4 lb)
HINT: Turn the counter drive gear right and left several
times before measuring the preload.
3. REMOVE O/D ONE±WAY CLUTCH AND OUTER RACE
(a) Remove the snap ring.
(b) Remove the retaining plate.
(c) Remove the O/D one±way clutch with outer race.
(d) Remove the 2 retainers from both sides of the O/D one±
way clutch.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±67
(e) Remove the O/D one±way clutch from the outer race.
HINT: Note the direction of the one±way clutch.
4. REMOVE NO.3 PLANETARY THRUST WASHER
5. REMOVE PLUGS FROM PLANETARY GEAR
Remove the 4 plugs with a magnetic finger.
NOTICE: Be careful not to lose them.
6. REMOVE ADJUSTING NUT AND LOCKING WASHER
(a) Pry off the locking washer.
(b) Using SST, loosen the adjusting nut.
SST 09350±32014 (09351±32080)
(c) Remove the adjusting nut and locking washer.
7. REMOVE INTERMEDIATE SHAFT BEARING
Using SST, press out the bearing from the shaft.
SST 09950±00020

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±68
8. REMOVE COUNTER DRIVE GEAR AND FRONT
BEARING
Press out the gear and bearing together.
9. REMOVE REAR BEARING
(a) Using SST, press out the bearing.
SST 09950±00020
(b) Tag the bearings to show the location for reassembly.
10. REMOVE O/D PLANETARY RING GEAR FROM
COUNTER DRIVE GEAR
(a) While pulling up the ring gear, compress the snap ring
with needle±nose pliers and remove it from the groove.
(b) Remove the ring gear from the counter drive gear.
(c) Remove the snap ring from the ring gear.

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±69
11. REMOVE OUTER RACES FROM COUNTER DRIVE
GEAR
(a) Drive out the 2 races with a brass bar and hammer.
(b) Tag the races to show the location for reassembly.
12. REMOVE SNAP RING FROM COUNTER DRIVE GEAR
Using a screwdriver, remove the snap ring.
OVERDRIVE PLANETARY GEAR
INSPECTION
MEASURE PLANETARY PINION GEAR THRUST
CLEARANCE
Using a feeler gauge, measure the planetary pinion gear
thrust clearance.
Standard clearance:
0.16±0.56 mm (0.0063±0.0220 in.)
Maximum clearance:
0.61 mm (0.0240 in.)
If the clearance is greater then the maximum, replace the
planetary gear assembly.
AX03Z±03

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±70
COUNTER DRIVE GEAR ASSEMBLY
1. INSTALL SNAP RING INTO COUNTER GEAR
Install the snap ring with a screwdriver.
2. INSTALL OUTER RACES INTO COUNTER DRIVE
GEAR
Using SST, press in the 2 outer races to both sides of the
gear.
SST 09350±32014 (09351±32120, 09351±32150)
HINT: Press in the 2 outer races until they touch the snap
ring. Tap the races in straight, so that they do not tilt.
3. INSTALL OVERDRIVE PLANETARY RING GEAR INTO
COUNTER DRIVE GEAR
(a) Install the snap ring to the ring gear.
(b) While pushing down the ring gear, squeeze the snap ring
end with needle±nose pliers, and install it into the groove.
4. INSTALL REAR BEARING
Using SST, press in the bearing onto the shaft.
SST 09350±32014 (09351±32120)
HINT: Press in the bearing until the side surface of the in-
ner race touches the planetary carrier.
AX040±03

AUTOMATIC TRANSAXLEOVERDRIVE UNIT ±
AX±71
5. INSTALL COUNTER DRIVE GEAR AND FRONT BEAR-
ING
(a) Install the gear onto the shaft, and mesh the ring gear with
the planetary pinions.
(b) Place the front bearing on to the shaft.
(c) Using SST, press in the bearing until there is slight play
between the bearings.
SST 09350±32014 (09351±32120)
HINT: Hold the ring gear to prevent it from falling.
6. INSTALL INTERMEDIATE SHAFT BEARING
Using SST, press in the bearing until it slightly touches the
front bearing of the counter drive gear.
SST 09350±32014 (09351±32120)
HINT: The counter drive gear can be turned lightly.
7. PLACE NEW LOCKING WASHER
8. INSTALL ADJUSTING NUT AND ADJUST PRELOAD
OF COUNTER DRIVE GEAR
(a) Hold the overdrive planetary gear in a vise with soft jaws.
(b) Using SST, tighten the adjusting nut until the following
gear starting load is reached on the tension gauge.
SST 09350±32014 (09351±32080)
Preload (at starting):
9.2±15.3 N (940±1,560 g, 2.1±3.4 lb)