TOYOTA CAMRY V20 1986 Service Information

AT3724
A540E
AT3725
AT3726
FlangePlate Disc
AT3556 AT3723
14. INSTALL SECOND COAST BRAKE BAND GUIDE
15. PLACE NO. 1 ONE-WAY CLUTCH
(a) Coat the thrust washer with petroleum jelly and
install it on the No. 1 one-way clutch. (A540E)
(b) Place the No. 1 one-way clutch onto the rear
planetary gear.
16. INSTALL SECOND BRAKE
(a) Install the flange, facing the flat end upward.
(b) Install the three discs and plates.
Install in order: P = Plate D = Disc
D-P-D-P-D-P
(c) Place the piston return spring into the case.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-135

AT0335
AT7761
AT3601
AT3727 AT0334
(d) Place the second brake drum into the case.
HINT: Align the groove of the drum with the bolt.
(e) Place the snap ring into the case so that end gap
is installed into the groove.
(f) While compressing the piston return springs over
the drum with hammer handles, install the snap
ring into the groove.
(g) Be sure that the end gap of the snap ring is not
aligned with one of cutouts.
17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the
second brake drum.
18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket and
confirm that the piston moves.
19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
(a) Coat the thrust washer with petroleum jelly and
install it on the sun gear input drum.
AT-136- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3728
AT3730
Outer Diameter Inner Diameter
A540E
Bearing45.5 (1.791)30.1 (1.185)
A540HBearing45.0 (1.772)30.0 (1.181)
Race45.0 (1.772)28.0 (1.102)
AT5036
A540H A540EA540E A540H
AT3551
AT5026
Race
(A540H)
Outer Diameter
Inner Diameter
A540E
Bearing45.5 (1.791) 30.1 (1.185)
A540HFront Race37.9 (1.492)22.0 (0.866)
Bearing36.1 (1.421)22.2 (0.874)
Rear Race35.0 (1.378)19.0 (0.748)
and HINT: The bearings are the same on the
side (A540E).
(b) Install the planetary gear onto the sun gear. Bearing and race:
mm (in.)
Bearing and race:(b) While turning the sun gear clockwise, install it into
the No. 1 one-way clutch.
20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT
HINT: After installing the oil seal ring, check that it
moves smoothly.
21. INSTALL FRONT PLANETARY GEAR
(a) Coat the races and bearings with petroleum jelly, and
install them onto the both sides of planetary gear.mm (in.)
22. INSTALL FRONT PLANETARY RING GEAR
(A540H)
Coat the race with petroleum jelly and install it onto the
tip of ring gear.
Race: Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-137

ThicknessOuter Diameter Inner Diameter
Bearing3.60 (0.1417) 45.9 (1.807)27.7 (1.091)
4.19 (0.1650) 47.1 (1.854)27.7 (1.091)
ThicknessOuter DiameterInner Diameter
Front Race0.8 (0.0315)
43.0 (1.693)30.5 (1.201)
1.4 (0.0551)
Bearing42.0 (1.654)28.9 (1.138)
Rear Race42.0 (1.654)27.1 (1.067) Outer Diameter
Inner Diameter
A540E Bearing47.6 (1.874)
31.4 (1.236)
A540HBearing36.1 (1.421) 22.2 (0.874)
Race37.9 (1.492)
22.0 (0.866)
AT5034
A540E A540H
AT5035
A540H A540E
AT3733
Thrust Washer
AT3734 AT0346
Bearing: A540Emm (in.)
Bearing and racemm (in.)
23. INSTALL SECOND COAST BRAKE BAND
(a) Place the band into the case.
(b) Install the pin through the oil pump mounting bolt
hole.
24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
(a) Coat the race and bearing with petroleum jelly and
install it onto rear side of the forward clutch.
(b) Coat the race and bearing with petroleum jelly and
install it onto front side of the forward clutch.
HINT: There are two different-thick races (A540H) and
bearings (A540E) for adjustment of the input shaft thrust
play.
Bearing and race: A540H
mm (in.)
(c) Coat the thrust washer with petroleum jelly and
install it with the oil groove facing upward onto the
direct clutch drum.
(d) Mesh the hub of the forward clutch with flukes of
the direct clutch discs.
HINT: Be careful that the bearing and thrust washer do
not get out of place.
AT-138- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3735
AT7700
AT3545
AT3736 AT3547
(e) Install the direct clutch and forward clutch into the
case.
HINT: Hold the direct clutch toward the forward clutch to
prevent the thrust washer from getting out of place.
(f) Check the distance between the direct clutch
drum and the sun gear input drum.
Distance: Approx. 3 mm (0.12 in.)
25. INSTALL OIL PUMP INTO CASE
(a) Coat a new O-ring with ATF and install it to the oil
pump.
(b) Place the oil pump through the input shaft, and
align the bolt holes of the pump body with the
transmission case.
NOTICE: Do not push on the oil pump strongly or the
oil seal ring will stick to the direct clutch drum.
(c) Install and tighten the seven bolts.
Torque: 225 kg-cm (16 ft-lb, 22 N-m)
26. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.
Thrust play: 0.13 - 0.90 mm (0.0051 - 0.0354 in.)
HINT: There are two different-thick bearings (A540E) or
races (A540H) for the end of stator shaft. If the thrust
play is in excess of standard, select one of them.
(A540E)
Bearing thickness: 3.60 mm (0.1417 in.)
4.19 mm (0.1650 in.)
(A 540H)
Race thickness: 0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-139

AT3543
SST
AT3541
AT3542 AT3544
CoverO-Rings Piston Spring
27. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
28. INSTALL SECOND COAST BRAKE PISTON
(a) Coat the new O-rings with ATF and install it to the
cover.
(b) Install the outer spring with the piston.
(c) Place the cover into the bore.
(d) Using SST, install the snap ring while pressing the
cover.
SST 09350-32014 (09351-32050)
(e) Check that the front end of the piston rod contacts
the center of the second brake band depression.
29. CHECK SECOND COAST BRAKE PISTON STROKE
(a) Apply a small amount of paint to the piston rod at
the point it meets the case shown in the illustration.
(b) Using SST, measure the piston stroke applying
and releasing the compressed air (4 - 8 kg/cm
2,
57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 in.)
If the stroke is more than specified, replace the piston
rod with a longer one.
Piston rod length: 95.2 mm (3.748 in.)
96.3 mm (3.791 in.)
It is still more than standard value, replace the brake
band with a new one.
AT-140- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3737
C1
B2C2
AT3539
SpringFree length
mm (in.)Outer diameter
mm (in.)Color
C
251.0 (2.008)18.0 (0.709)
Red
B
258.5 (2.303)15.2 (0.598)
Orange
C
1
Outer71.2 (2.803)24.4 (0.961)
Blue
Inner43.4 (1.709)17.8 (0.701)
Light green
AT3537
AT3536 AT3538
30. INSTALL ACCUMULATOR PISTONS AND SPRINGS
(a) Install the new O-rings to the pistons.
(b) Install the springs and pistons into the bores.
(c) Place the cover with a new gasket and gradually
tighten the bolts a little a time in sequence.
HINT: Each bolt length (mm, in.) is indicated in the figure.
Torque: 100 kg-cm (7 ft-lb, 10 N-m)
31. PLACE NEW SECOND BRAKE APPLY GASKET
32. INSTALL THROTTLE CABLE AND SOLENOID WIRE
33. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip
the cable end into the slot.
(b) Lower the valve body into place.
NOTICE: Do not entangle the solenoid wire.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-141

AT3738
Tube
AT3534RetainerClamp
AT3739
AT4506
Only
A540H
AT4489
(c) Install and tighten the ten bolts.
HINT:
Each bolt length (mm, in.) is indicated in the figure.
Hand tighten the ten bolts first, then torque with a
torque wrench.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
34. INSTALL B
3 APPLY TUBE
NOTICE: Be careful not to bend or damage the tube.
35. INSTALL CONNECTOR CLAMP AND TUBE RETAINER
HINT: Each bolt length (mm, in.) is indicated in the figure.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
36. CONNECT SOLENOID CONNECTORS
37. INSTALL OIL TUBES
(A540E)
Using a plastic hammer, install the tubes into the posi-
tions indicated in the figure.
(A540H)
(a) Using a plastic hammer, install the tubes into the
positions indicated in the figure.
(b) Install the bolt.
Torque: 55 kg-cm (48 in.-lb, 5.4 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
NOTICE: Be careful not no bend or damage the tubes.
AT-142- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT5049
AT3532
AT3741
AT3742 AT3757
38. INSTALL MANUAL VALVE BODY AND DETENT
SPRING
HINT: Each bolt length (mm, in.) is indicated in the figure.
(a) Align the manual valve with the pin on the manual
shaft lever.
(b) Lower the manual valve body into place.
(c) Hand tighten the five bolts first. Then, tighten them
with a torque wrench.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
(d) Place the detent springs on the manual valve body
and hand tighten the two bolts first.
Then, tighten them with a torque wrench.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
(e) Check that the manual valve lever is touching the
center of the detent spring tip roller.
39. INSTALL TUBE BRACKET AND OIL STRAINER
Each bolt length (mm, in.) is indicated in the figure.
Torque:
Tube bracket 100 kg-cm (7 ft-lb, 10 N-m)
Oil strainer 110 kg-cm (8 ft-lb, 11 N-m)
40. INSTALL MAGNETS IN PLACE AS SHOWN
NOTICE: Make sure that the magnets do not interfere
with the oil tubes.
41. INSTALL OIL PAN WITH NEW GASKET
Torque: 50 kg-cm (43 in.-lb, 4.9 N-m)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-143

AT5636
Speed Sensor A540H
AT3529
AT3743
Neutral Start Switch Locking
Plate
AT7762
Groove Neutral
Basic
Line
AT3530
A540E42. (A540E)
INSTALL SPEED SENSOR
(a) Install a new O-ring to the speed sensor.
(b) Install the speed sensor to the transaxle case.
(c) Tighten the bolt.
(d) Connect the sensor connector.
43. (A540H)
INSTALL VEHICLE SPEED SENSOR
(a) Install a new O-ring to the vehicle speed sensor.
(b) Install the vehicle speed sensor to the transaxle
case.
(c) Install and tighten the bolt.
44. INSTALL THROTTLE CABLE RETAINING PLATE
45. INSTALL SOLENOID WIRE
46. INSTALL NEUTRAL START SWITCH
(a) Install the neutral start switch to the manual valve
shaft.
(b) Place the new locking plate and tighten the nut.
(c) Stake the nut with locking plate.
(d) Install the two bolts.
(e) Adjust the neutral start switch.
HINT: Align the groove and neutral basic line.
(f) Tighten the two bolts.
AT-144- AUTOMATIC TRANSAXLEInstallation of Component Parts