TOYOTA CAMRY V20 1986 Service Information

AT3698
Seal
Packing A540E
AT4577
A540H
AT4601
A540H
AT3583
A540E
AT4965
Sleeve A540H(A540H)
Be sure to install the ring gear mount case sleeve and
outer race into place.
10. INSTALL CARRIER COVER
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the carrier
cover and transaxle case.
(b) Apply seal packing to the carrier cover as shown.
Seal packing: Part No. 08826-00090, THREE BOND
1281 or equivalent
HINT: Install the carrier cover within ten minutes after
applying seal packing.
(c) Install the two apply gaskets.
(d) Install and torque the eleven bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-125

New BearingReused Bearing
A540E2.8 - 4.4
(2.4 - 3.8, 0.3 - 0.4)1.4 - 2.2
(1.2 - 1.9, 0.1 - 0.2)
A540H2.3 - 3.7
(2.0 - 3.2, 0.2 - 0.4)1.2 - 1.9
(1.0 - 1.6, 0.1 - 0.2)
AT4170
AT4171
AT3700
Adjusting Shim
MarkThicknessMarkThickness
0
1
2
3
4
5
6
7
82.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)
2.35 (0.0925)
2.40 (0.0945)9
A
B
C
D
E
F
G
H2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)
2.70 (0.1063)
2.75 (0.1083)
2.80 (0.1102)
2.85 (0.1122)
A540H
AT4173
mm (in.)
11. ADJUST SIDE SEARING PRELOAD
(a) Remove any packing material on the contacting
surfaces of the LH bearing retainer and transaxle
case.
HINT: Do not apply seal packing yet.
(b) Install the LH bearing retainer and torque the six
bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(c) Snap down the bearings by turning the differential
case several times.
(d) Using a torque meter, measure the differential total
preload.
Total preload (at starting)
Add drive pinion preload
kg-cm (in.-lb, N-m)
If the preload is not within specification, replace the
adjusting shim in the LH bearing retainer with another
thickness one.
AT-126- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT4563
AT3711
AT3712
SST
AT4170
12. INSTALL LH BEARING RETAINER
(a) Remove the six bolts and LH bearing retainer.
(b) Remove any packing material on the contacting
surfaces of LH bearing retainer, transaxle case
and carrier cover.
(c) Apply the seal packing to the transaxle case and
carrier cover as shown.
Seal packing: Part No. 08826 - 00090, THREE
BOND 1281 or equivalent
HINT: Install the LH bearing retainer with ten minutes
after applying seal packing.
(d) Install the LH bearing retainer.
(e) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND
1324 or equivalent
(f) Tighten the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(g) Snap down the bearings.
(h) Recheck the differential total preload.
AT4170
13. INSTALL NEW OIL SEAL
(a) Place the oil baffle onto the LH bearing retainer.
(b) Using SST, driven in a new oil seal until its end is
flush with the surface of the LH bearing retainer.
SST 09223-15010
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-127

AT3581
A540E
AT3586AT3713
Seal
Packing A540E
14. (A540E)
INSTALL RH RETAINER
(a) Remove any packing material on the contacting
surfaces of RH retainer and transaxle case.
(b) Apply the seal packing to the RH retainer as
shown.
Seal packing: Part No. 08826-00090, THREE BOND
1281 or equivalent
HINT: Install the RH retainer within ten minutes after
applying seal packing.
(c) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324
or equivalent
(d) Tighten the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
15. INSTALL DRIVE PINION CAP
(a) Install a new O-ring to the cap.
(b) Install the drive pinion cap to the transaxle case.
AT-128- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT7759
AT0090
AT3576
Manual
Valve LeverParking
Lock Rod
AT3574 AT2731
Lock PawlPin
INSTALLATION OF 4-SPEED GEAR UNIT
1. INSTALL PARKING LOCK PAWL
(a) Place the parking lock pawl onto the case.
Hook the spring ends to the case and pawl.
(b) Install the pin into the hole of the case through the
spring and pawl.
2. INSTALL MANUAL VALVE SHAFT
(a) Coat the oil seal lip with the MP grease.
(b) Install the manual valve shaft oil seal to the case.
(c) Assemble a new collar to the manual valve lever.
(d) Install the manual valve shaft to the transmission
case through the manual valve lever.
(e) Install the parking lock rod.
(f) Using a pin punch, drive in the roll pin until its sur-
face is flush with the manual valve lever surface.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-129

AT5025
Retaining
Spring
AT0312
AT0969
AT2757AT0093
(g) Match the collar hole to the lever calking hollow
and calk the collar to the lever.
(h) Install the retaining spring.
3. INSTALL PARKING LOCK PAWL BRACKET
Torque: 75 kg-cm (65 in.-lb, 7.4 N-m)
4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the
manual valve lever is in the P range.
5. INSTALL FIRST AND REVERSE BRAKE PISTON TO
TRANSMISSION CASE
(a) Coat the new O-rings with ATF.
(b) Install the two O-rings on the piston.
AT-130- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT0198 AT0376
SST
AT0199
AT3572
AT2729 AT0197
(c) Push the piston into the bore of the case, facing
the spring seat upward.
6. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring on the piston.
(b) Place SST, and compress the return spring evenly
by tightening the bolt gradually.
SST 09350-32014 (09351-32040)
(c) Install snap ring. Visually check to make sure it is
fully seated and centered by the three lugs on the
spring retainer.
Be sure the end gap of snap ring is not aligned with
the spring retainer claw.
(d) Remove SST.
7. INSTALL SNAP RING TO TRANSAXLE CASE
8. INSTALL OVERDRIVE UNIT
(a) Install the overdrive brake apply gasket and over-
drive clutch apply gasket.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-131

AT7731
AT3714
AT4169
AT7760 AT2728
(b) Install the overdrive brake drum to the case.
(c) Install the new case gasket to the case.
(d) Make sure that the length from the top surface of
the case to the counter driven gear top surface
should be about 24 mm (0.94 in.)
(e) Place the new gasket onto the transaxle case.
(f) Install the overdrive assembly with overdrive case
to the transaxle case.
(g) Coat the threads of 23 mm (0.91 in.) bolts with
sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324
or equivalent.
(h) Install and tighten the thirteen bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
9. CHECK INTERMEDIATE SHAFT END PLAY
(a) Make sure that the intermediate shaft has thrust
play in axial direction.
Thrust play: 0.47 - 1.50 mm (0.0185 - 0.0591 in.)
If the thrust play is not within specification, check the
installation of intermediate shaft.
(See page AT-83)
(b) Make sure that the intermediate shaft turns
smoothly.
AT-132- AUTOMATIC TRANSAXLEInstallation of Component Parts

Outer Diameter
Inner Diameter
A540E
Bearing38.7 (1.524)
22.6 (0.890)
A540HFront Race37.3 (1.469)
24.1 (0.949)
Bearing37.6 (1.480)
24.0 (0.945)
Rear Race37.6 (1.480)
22.2 (0.874)
AT3717
AT3716
AT3718
Plate
DiscFlange
AT3719AT5037
A540H A540E
Bearing and race:mm (in.)
10. INSTALL REAR PLANETARY GEAR
(a) Install the rear planetary ring gear.
(b) (A540E)
Place the bearing onto the ring gear.
(c) (A540H)
Coat the races and bearing with petroleum jelly
and install them onto the ring gear.
(d) Coat the thrust washer with petroleum jelly and
place it onto the rear planetary gear.
(e) Install the rear planetary gear.
11. INSTALL DISCS, PLATES AND FLANGE OF FIRST
AND REVERSE BRAKE
(a) Install the seven plates and seven discs.
Install in order: P = Plate D = Disc
A540E: P-D-P-D-P-D-P-D-P-D-P-D-P-D
A540H: P-D-P-D-P-D-P-D-P-D-P-D
(b) Install the flange, facing the flat end downward.
(c) Install the snap ring.
HINT: Be sure that the end gap of the snap ring is not
aligned with one of cutouts.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-133

AT3602
AT3720
AT3721
SST
AT5022
Thrust
Washer
AT3563
12. CHECK FIRST AND REVERSE BRAKE
(a) Check the operation of the first and reverse brake
piston.
Apply compressed air into the case passage and confirm
that the piston moves.
(b) Using a filler gauge, check the pack clearance of
the first and reverse brake.
Clearance: A540E
0.85 - 2.05 mm (0.033 - 0.081 in.)
A540H
1.04 - 2.16 mm (0.041 - 0.085 in.)
13. INSTALL NO. 2 ONE-WAY CLUTCH INTO CASE
(a) Place the No. 2 one-way clutch with the shiny
side of flange upward.
(b) Install the one-way clutch while turning the plane-
tary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If can not turn the planetary gear clockwise, check the
installation of the one-way clutch.
(c) Install the snap ring.
HINT: Be sure that the end gap of the snap ring is not
aligned with one of cutouts.
(d) (A540H only)
Coat the thrust washer with petroleum jelly and
install it onto the rear planetary gear.
AT-134- AUTOMATIC TRANSAXLEInstallation of Component Parts