TOYOTA CAMRY V20 1986 Service Information

AT3527
Elbow UnionA540H
AT3745
AT4223
Intermediate Shaft A540H
AT7763
A540H
AT3744Manual Shift Lever
47. INSTALL MANUAL SHIFT LEVER
48. INSTALL UNION AND ELBOW
(a) Install the new O-rings to the union and elbow.
(b) Install the union and elbow to the transaxle case.
Torque: 275 kg-cm (20 ft-lb, 27 N-m)
HINT: Install the elbow at right angles to the bottom of
the transaxle case.
49. (A540H)
INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE
SHAFT
(a) Install a new snap ring to the shaft groove.
(b) Using a plastic hammer, install the shaft.
HINT: Keeping the intermediate shaft on the pinion shaft
of differential, measure the point in the illustration.
Protrusion length (Reference): 255.5 mm (10.059 in.)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-145

AT4576
A540H
AT4600
A540H
AT4309
A540H
AT4221
A540H50. (A540H)
INSTALL APPLY GASKET
Install a new apply gasket to the differential carrier cover.
51. (A540H)
INSTALL TRANSFER ASSEMBLY
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transfer
and transaxle.
(b) Apply seal packing to the transaxle as shown in the
illustration.
Seal packing: Part No. 08826 - 00090, THREE BOND
1281, or equivalent
HINT: Install the transfer assembly as soon as the seal
packing is applied.
(c) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324
or equivalent.
(d) Install and torque the five nuts and three bolts.
Torque: 700 kg-cm (51 ft-lb, 69 N-m)
52. (A540H)
INSPECT MODE SELECT LEVER POSITION
After finishing inspection or repair the transaxte, be sure
the select lever position to FREE mode and attach the
lock bolt.
AT-146- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT4416
Dust Deflector Extension
Housing
AT4414
Speed Sensor
AT4415
Dynamic Damper
AT4417
SST
AT4309
DISASSEMBLY OF COMPONENT PARTS
1. REMOVE TRANSFER MODE SELECT LEVER AND
ROD
2. REMOVE REAR WHEEL SPEED SENSOR
(a) Remove the bolt and pull out the speed sensor.
(b) Remove the O-ring from speed sensor.
3. REMOVE DYNAMIC DAMPER
Remove the four bolts and dynamic damper.
4. REMOVE EXTENSION HOUSING
(a) Remove the dust deflector from the extension
housing.
(b) Remove the four bolts and extension housing.
(c) Remove the O-ring from the extension housing.
(d) Using SST, remove the oil seal.
SST 09308-00010
- TRANSFER (A540H)Disassembly of Component PartsTF-3

AT4333
AT4418
O-ring Gasket
AT4308
AT4420AT4419
SST
5. REMOVE TRANSFER RIGHT CASE RETAINER
(a) Remove the five bolts.
(b) Using a plastic hammer, remove the right case
retainer.
(c) Remove the O-ring and apply gasket from the
right case retainer.
6. REMOVE TRANSFER INSPECTION HOLE COVER
Remove the three bolts and inspection hole cover.
7. CHECK PRELOAD
(a) Using SST and a spring tension gauge, measure
the driven pinion preload of the backlash between
the driven pinion and ring gear.
SST 09326-2001 1
Driven pinion preload (at starting):
0.9 - 1.4 kg (2.0 - 3.1 lb, 8.8 - 13.7 N)
(b) Using SST and a spring tension gauge, measure
the total preload.
SST 09326-2001 1
Total preload (at starting):
Add driven pinion preload
0.5 - 0.9 kg (1.1 - 2.0 lb, 4.9 - 8.8 N)
8. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
CHECK TOOTH CONTACT
(See page
TF-34)
TF-4- TRANSFER (A540H)Disassembly of Component Parts

AT4423
AT4424
Gasket
AT4507
Strainer Drive Gear
AT4421
ShimO-ring
9. REMOVE DRIVEN PINION BEARING CAGE
(a) Remove the six bolts and bearing cage.
(b) Remove the O-ring and the shims from the bearing
cage.
10. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and right case.
AT4422
11. REMOVE CENTER DIFFERENTIAL ASSEMBLY
12. REMOVE APPLY GASKET
Remove the apply gasket from the left case.
13. REMOVE OIL PUMP DRIVEN GEAR AND OIL PUMP
STRAINER
(a) Remove oil pump driven gear.
(b) Remove the bolt and oil pump strainer.
(c) Remove the O-ring from the oil pump strainer.
- TRANSFER (A540H)Disassembly of Component PartsTF-5

AT4509
Adjusting NutSST
Oil Reserver
AT7764
AT4510
AT4511 AT4508
Bolt Lock Plate
14. REMOVE ADJUSTING NUT LOCK PLATE
(a) Remove the bolt and nut lock plate from the right
case.
(b) Remove the O-ring from the bolt.
15. REMOVE DIFFERENTIAL RIGHT SIDE BEARING
OUTER RACE
(a) Using SST, remove the adjusting nut and oil re-
server from the right case.
SST 09318-12010
(b) Using a brass bar, remove the outer race.
16. REMOVE DIFFERENTIAL LEFT SIDE BEARING
OUTER RACE
Using SST, remove the outer race and plate washer.
SST 09308-00010
17. REMOVE LEFT CASE OIL SEAL
Using SST, remove the oil seal.
SST 09308-00010
TF-6- TRANSFER (A540H)Disassembly of Component Parts

AT4323r Non-reusable part kg-cm (ft-lb, N-m) * For use SSTTransfer Pinion Spacer Bearing CageRear Side Bearing Union 1,100 (80,108)
*1,000 (72, 98) r Lock Nut Front Side Bearing
Driven Pinion
AT7765
AT7766
SST
Driven Pinion Bearing Cage
COMPONENTS
DISASSEMBLY OF DRIVEN PINION BEARING
CAGE
1. REMOVE LOCK NUT
(a) Using a chisel and hammer, unstake the lock nut.
(b) Using SST, remove the lock nut.
SST 09326-2001 1
NOTICE: Using soft jaws, hold the driven pinion in a
vise.
: Specified torque
- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)TF-7

AT7768
SST
AT7769
AT7770 AT7771
SSTSST Front Rear
AT7772
SST
AT7767
2. REMOVE DRIVEN PINION
Using a press, remove the driven pinion, rear side bearing
and spacer.
3. REMOVE FRONT SIDE BEARING
Using a press and SST, remove the front side bearing.
SST 09950-00020
4. REMOVE BEARING OUTER RACES
Using a brass bar and hammer, remove the two bearing
outer races.
ASSEMBLY OF DRIVEN PINION BEARING
CAGE
1. INSTALL BEARING OUTER RACES
Using a press and SST, install the two bearing outer
races to the bearing cage.
SST
Front side:
09608-35014 (09608-06020, 09608-06120)
Rear side:
09608-30022 (09608-05010, 09608-00050)
2. INSTALL DRIVEN PINION FRONT SIDE BEARING
Using a press and SST, install the front side bearing.
SST 09506-35010
TF-8- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)

AT7774
SST
AT7775
Fulcrum
Length
SST
AT7776
SST
AT7773
3. INSTALL SPACER
Install a new spacer to the driven pinion.
4. INSTALL DRIVEN PINION REAR SIDE BEARING
(a) Install the bearing cage to the driven pinion.
(b) Using a press and SST, install the rear side bearing
to the driven pinion.
SST 09506-35010
5. ADJUST DRIVEN PINION PRELOAD
(a) Using SST, torque a new nut.
SST 09326-2001 1
Torque: 1,000 kg-cm (72 ft-lb, 98 N-m)
HINT: Use a torque wrench with a fulcrum length of
42.5 cm (16.732 in.).
(b) Using a spring tension gauge and SST, measure
the preload.
SST 09326-2001 1
HINT: Turn the driven pinion right and left two or three
times to allow the bearings to settle.
Preload (at starting):
New bearing
1.8 - 2.9 kg (4.0 - 6.4 lb, 18 - 28 N)
Reused bearing
0.9 - 1.4 kg (2.0 - 3.1 lb, 9 - 14 N)

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

If preload is less than specification, retighten
the nut 5° - 10°at a time until the specified
preload is rechecked.
If the maximum torque is exceeded while retightening
the nut, replace the bearing spacer and repeat the pre-
load procedure.
Do not back off the pinion nut to reduce the preload.
Maximum torque: 2,400 kg-cm (174 ft-lb, 235 N-m)
NOTICE: Using the soft jaws, hold the bearing cage in
a vise.
- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)TF-9

AT7777
6. STAKE LOCK NUT
Using a pin punch and hammer, stake the nut.
TF-10- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)