TOYOTA CAMRY V20 1986 Service Information

AT4429
AT4317
AT7756
Oil
Bath 212°F (100°C)
AT4297
Matchmark
AT4337Matchmark
8. INSTALL FRONT DIFFERENTIAL CASE
(a) Install the front differential case to the ring gear
mounting right case.
HINT: Align the flukes of the discs in the hydraulic multi-
plate clutch.
(b) Install the No. 2 thrust washer.
9. INSTALL RING GEAR
(a) Clean the contact surface of the ring gear mounting
left case.
(b) Heat the ring gear to about 212°F (100°C) in an oil
bath.
NOTICE: Do not heat the ring gear above 230°F (110°C).
(c) Clean the contact surface of the ring gear with
cleaning solvent.
(d) Quickly install the ring gear on the ring gear mount-
ing left case.
HINT: Align the matchmarks on the ring gear mounting
left case and the ring gear.
(e) Install the ring gear and ring gear mounting left
case on the ring gear mounting right case. Install
the twelve bolts.
HINT: Align the matchmarks on the ring gear mounting
left case and contact the right case.
(f) Tighten the set bolts uniformly and a little at a time.
Torque the bolts.
Torque: 1,260 kg-cm (91 ft-lb, 124 N-m)
AT-1 16- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)

AT7758
AT4301
Oil Seal Ring
AT4302
Sleeve
AT4299
Outer Race
AT7757
10. CHECK OPERATION OF FRONT DIFFERENTIAL
Check that the front differential turns smoothly.
11. INSTALL SPEEDOMETER DRIVE GEAR
(a) Place the speedometer drive gear on the ring gear
mounting case.
(b) Install the snap ring.
12. INSTALL OIL SEAL RINGS
Install the four oil seal rings to the ring gear mounting
right case.
13. INSTALL RING GEAR MOUNTING CASE SLEEVE
14. INSTALL RIGHT SIDE BEARING OUTER RACE
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)AT-1 17

AT3683
SST A540E
AT3684
SST
TA0041
SST
TA0042
SST
TA0043
SST
DISASSEMBLY OF DRIVE PINION
1. REMOVE DRIVE PINION SHAFT BEARING
Using SST and a press, remove the bearing.
SST 09950-00020
2. (A540E)
REMOVE OIL SEALS FROM CAGE
Using SST, press out the two oil seals.
SST 09325-12010
3. REMOVE PINION SHAFT BEARING OUTER RACE
FROM CAGE
Using SST, remove the outer race.
SST 09612-65014
4. REMOVE COUNTER DRIVEN GEAR BEARING
Using SST and a press, remove the bearing.
SST 09950-00020
ASSEMBLY OF DRIVE PINION SHAFT
COMPONENTS
1. INSTALL COUNTER DRIVEN GEAR BEARING
Using SST, press in a new bearing.
SST 09350-32014 (09351-32090)
AT-1 18- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)

AT3686 AT3803
A540E
AT3687
SST A540E
AT3688
SST
AT3689
SST
AT3685
SST A540E
2. (A540E)
INSTALL OIL SEALS TO CAGE
(a) Using SST, press in a new oil seal with the lip facing
downward.
SST 09325-12010
Oil seal press in depth (from flat end):
8 mm (0.31 in.)
(b) Check the oil seal press in depth.
Oil seal press in depth: 4.3 mm (0.169 in.)
(c) With the oil seal lip facing upward, use SST to
press in a new oil seal until its end is flush with the
surface of the cage.
SST 09325-12010
(d) Coat the oil seal lips with MP grease.
3. INSTALL SHAFT BEARING OUTER RACE TO CAGE
Using SST, press the outer race into the cage.
SST 09350-32014 (09351-32111)
4. INSTALL DRIVE PINION SHAFT BEARING
Using SST, press in the bearing.
SST 09350-32014 (09351-32100)
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)AT-1 19

AT4672r Non-reusable part kg-cm(ft-lb, N-m)
: Specified torque
260 (19, 25)
Dynamic Damper
260 (19, 25)
r Oil Seal Transfer Left Case
400 (29, 39)700 (51, 69)
r GasketTransfer Extension
Housing r Apply Gasket Plate Washer Left Side Bearing
Outer RaceTransfer Inspection
Hole Cover r Oil Seal
160 (12, 16)r O-Ring Rear Wheel
Speed Sensor
400 (29, 39) 55 (48 in.-lb, 5.4)
Dawel PinRing Gear Mounting
Case and Center
Differential Case Transfer Right Case
450 (33, 44)55 (48 in.-lb, 5.4)
Oil Strainer Oil Reserver Bearing Adjusting NutO-Ring
Adjusting Nut Lock Pater O-RingOil Pump Driven Gear r Apply Gasket
55 (48 in.-lb, 5.4)
Mode Select Lever
and Rod Dawel Pin
73 (63 in.-lb, 7.2)Lever Guide
115 (8, 11)Transfer Right Case Retainer
300 (22, 29)
r O-Ring ShimDriven Pinion
Bearing Cage
Extension Housing
Dust Deflector
Drain PlugRight Side Bearing
Outer Race O-Ring
Transfer (A540H)
COMPONENT PARTS
TF-2- TRANSFER (A540H)Component Parts

INSTALLATION OF COMPONENT PARTS
Disassembly, inspection and assembly of each component group have been indicated in the pre-
ceding 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: DEXRON
II (A540E)
Type T (08886 - 00405) or equivalent (A540H)
GENERAL INSTALLATION NOTES:
1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful
inspection before assembly because even a small nick could cause fluid leakage or affect
performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least fifteen
minutes.
3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
AT-120- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT5039
mm (in.)
A540E
ABCDEF
Bearing
(with race)Outer
DiameterSee page
AT-35447.6
(1.874)45.5
(1.791)
u38.7
(1.524)54.0
(2.126)
Inner
Diameter27.7
(1.091)31.4
(1.236)30.1
(1.185)u22.6
(0.890)39.4
(1.551)
A540H A'
B' C' D' E' F'
Front
Bearing
RaceOuter
Diameter43.0
(1.693)37.9
(1.492)u45.0
(1.772)37.3
(1.469)
Inner
Diameter30.5
(1.201)22.0
(0.866)u28.0
(1.102)24.1
(0.949)
Thrust
BearingOuter
Diameter42.0
(1.654)36.1
(1.421)u45.0
(1.772)37.6
(1.480)46.3
(1.823)
Inner
Diameter28.9
(1.138)22.2
(0.874)
u30.0
(1.181)24.0
(0.974)26.2
(1.031)
Rear
Bearing
RaceOuter
Diameter42.0
(1.654)35.7
(1.406)35.0
(1.378)37.6
(1.480)43.0
(1.693)
Inner
Diameter27.1
(1.067)23.0
(0.906)19.0
(0.748)22.2
(0.874)24.5
(0.965)
8. Be sure to install the thrust bearings and races in the correct direction and position.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-121

AT3691
A540E
AT3692
AT3595
SST
AT3594
A540E
AT3605
INSTALLATION OF DIFFERENTIAL AND
DRIVE PINION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
(a) Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with the
pinion shaft. (A540E)
(b) Install the two new O-rings to the bearing cage.
(A540E)
(c) Coat the O-rings with ATF. (A540E)
(d) Using a hammer and brass bar, slightly tap the
bearing cage into the transaxle case until the
snap ring groove in the bore can be seen.
(e) Using SST, install snap ring into the bore.
SST 09350-32014 (09351-32050)
2. (A540E)
PLACE SENSOR ROTOR ONTO DRIVE PINION SHAFT
AT-122- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3593
Oil SlingerSpacer
AT3693
Outer Race SSTSST
AT3694
SST (a) SST (b) Counter
Drive Gear
AT3695
SST
AT4175
Spacer A540H3. (A540H)
INSTALL DRIVE PINION BEARING NO. 2 SPACER
4. PLACE OIL SLINGER AND NEW SPACER
HINT: Install the spacer with the small end downward.
5. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350-32014 (09351-32100, 09351-32140)
6. INSTALL COUNTER DRIVEN GEAR
(a) Place SST into the transaxle hole to hold the drive
pinion shaft.
SST (a) 09350-32014 (09351-32130, 09351-32150)
(b) Using SST, press in the counter driven gear until
slightly thickness between the counter driven gear
bearing and outer race.
SST (b) 09350-32014 (09351-32140)
7. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION
PRELOAD
(a) Install the new lock nut.
(b) Using SST to hold the gear, tighten the nut.
Torque: 2,100 kg-cm (152 ft-lb, 206 N-m)
SST 09330-00021, 09350-32014 (09351-32032)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-123

AT3989
AT3697
Shim Outer Race A540E
AT3585
A540E
AT3588
(c) Turn the gear counterclockwise and clockwise sev-
eral times.
(d) Using a torque meter, measure the preload of the
drive pinion.
Drive pinion preload (at starting):
New bearing
10 - 16 kg-cm
(8.7 - 13.9 in.-lb, 1.0 - 1.6 N-m)
Reused bearing
5 - 8 kg-cm
(4.3 - 6.9 in.-lb, 0.5 - 0.8 N-m)
If the preload is greater than specified,
replace the bearing spacer.
If the preload is less than specified, retigh-
ten the nut 130 kg-cm (9 ft-lb, 13 N-m) at
a time until the specified 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: 3,600 kg-cm (260 ft-lb, 353 N-m)
(e) If the preload is adjusted within specification, make
a note of it.
(f) Stake the lock nut.
8. (A540E)
PLACE OUTER RACE AND SHIM ONTO RH SIDE
BEARING
9. PLACE DIFFERENTIAL CASE INTO TRANSAXLE
CASE
(A540E)
Be sure to install the shim and outer race into place.
AT-124- AUTOMATIC TRANSAXLEInstallation of Component Parts