differential TOYOTA CAMRY V20 1986 Service Information

AT5032
(A540H)
The A540H automatic transaxle design is based on the A540E automatic transaxle and equipped with a
center differential and transfer.
This transaxle has the same hydraulic multiplate clutch in the center differential limiting control mecha-
nism as the A241H automatic transaxle on the Corolla All-Trac/4WD Station Wagon. The fluid pressure
acting on the hydraulic multiplate clutch of the A540H is controlled by the ECT ECU (Electronic Control
Unit) according to the vehicle driving conditions. As a result, torque is distributed to the front and rear
wheels appropriately at all times to maximize the overall performance of the 4WD vehicle.
NOTICE: Special handling methods are necessary for full-time 4WD vehicles during inspection and
maintenance. Instructions concerning these handling methods are given on Camry Repair Manual
(Pub. No. RM199U) on page IN-8.
Hydraulic Multiplate ClutchTransfer Front DifferentialCenter
Differential 4-Speed Planetary Gear
Unit and Hydraulic
Control SystemNo. 1 and No. 2 Center Differential
Control Solenoid ValveCenter Differential ControlECT
ECU No. 1 and No. 2 Shift Control
Solenoid Valves and Lock-up
Control solenoid ValveEngine ECU
Throttle Position
Sensor
Stop Light Switch
Vehicle Speed
Sensors
Mode Select Switch
Neutral Start Switch
O/D Main Switch
Center Deff. Control
Switch Shift Control Sectional View
Sensors
- AUTOMATIC TRANSAXLEDescriptionAT-3

VALVE BODY
Hydraulic Control System

A540E, A540H
The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accu-
mulators, the clutches and brakes, and the governor valve as well as the fluid passages which connect all
of these components.
Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hy-
draulic pressure acting on the torque converter, clutches and brakes in accordance with the vehicle driving
conditions.
There are three solenoid valves on the valve body.
The No. 1 and No. 2 solenoid valves are turned on and off by signals from ECU to operate the shift valves
and change the gear shift position.
The No. 3 solenoid valve is operated by signals from the ECU to engage or disengage the lock-up clutch
of the torque converter.

A540H
There are two center differential control solenoid valves on the transfer.
The solenoid valves are adjusting the center differential control pressure.
HYDRAULIC CONTROL SYSTEM
Hydr. pressure control
OIL PUMP
CLUTCHES & BRAKESFluid passage switchingPlanetary gear unit
Torque converter
Throttle Cable
SOLENOID VALVES
ECU
AT-8- AUTOMATIC TRANSAXLEOperation

r Non-reusable part

Precoated part
AT3526
kg-cm (ft-lb, N-m) : Specified torque
Differential Case Assembly 195 (14, 19)Shim See page AT-123 r Lock NutOuter RaceOuter Race Oil Slinger400 (29, 39)r Gasket r SpacerFiller Plug Sensor
Rotor r O-Ringr Gasket Carrier CoverRH Retainer Drive
Pinion Bearing
Case195 (14, 19) r O-RingDrive Pinion Cap
A540E
Counter Driven GearSnap Ring
LH Side Bearing
RetainerDrain Plug
COMPONENTS (Cont'd)
AT-16- AUTOMATIC TRANSAXLERemoval of Component Parts

AT4677
r Non-reusable part

Precoated part
: Specified torque kg-cm (ft-lb, N-m)
Front Differential Assembly 195 (14, 19)Oil Seal Ring Outer RaceSnap Ring r Lock NutLH Side Rearing
Retainer Outer RaceRing Gear Mounting
Case Sleeve Oil SlingerIntermediate Shaft 400 (29, 39) Counter Driven Gearr Gasket
r Spacerr O-Ring r Apply Gasket
Plug Snap RingDrive PinionCarrier Cover Plug
r O-Ring r O-Ring Bearing
CageVehicle
Speed SensorTransfer
Assembly r O-Ringr Apply Gasket Drive Pinion Cap
A540H
Drain Plug
Plugr O-Ring
Drive Pinion
No. 2 Spacer
COMPONENTS (Cont'd)
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-17

AT4600
A540H
AT4221
Gasket Apply
A540H
AT4222
SSTBolt and Washer
A540H
AT3527
ElbowUnionA540H
AT3528
Manual Shift
Lever Neutral Start Switch
SEPARATE BASIC SUBASSEMBLY
1. (A540H)
REMOVE TRANSFER ASSEMBLY
(a) Remove the five nuts and three bolts.
(b) Using a plastic hammer, remove the transfer as-
sembly form the transaxle.
2. (A540H)
REMOVE APPLY GASKET
3. (A540H)
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE
SHAFT
(a) Screw in suitable bolt with washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate
shaft.
SST 09520-32012
4. REMOVE UNION AND ELBOW
(a) Using an open end wrench, remove the union and
elbow.
(b) Remove the O-rings from the union and elbow.
5. REMOVE NEUTRAL START SWITCH
(a) Remove the manual shift lever.
(b) Pry off the lock washer and remove the manual
valve shaft nut.
(c) Remove the two bolts and pull out the neutral start
switch.
AT-18- AUTOMATIC TRANSAXLERemoval of Component Parts

AT4170
AT4174
AT3581
A540E
AT3582
A540E
AT4171
REMOVAL OF DIFFERENTIAL COMPONENT
PARTS
1. MEASURE DIFFERENTIAL TOTAL PRELOAD
Using a torque meter measure the total preload, and
make a note of it.
2. REMOVE LH BEARING RETAINER
(a) Remove the six bolts.
(b) Using a large screwdriver, remove the LH bearing
retainer.
NOTICE: Wrap the screwdriver in a rag, etc. to avoid
damage to the case and retainer.
3. (A540E)
REMOVE RH RETAINER
(a) Remove the six bolts.
(b) Using a large screwdriver, remove the RH retainer.
NOTICE: Wrap the screwdriver in a rag, etc. to avoid
damage to the case and retainer.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-33

AT3583
A540E
AT4173
A540H
AT3584
A540E
AT3585
A540E
AT4232
A540H
4. REMOVE CARRIER COVER
(a) Remove the eleven bolts.
(b) Tap the carrier cover with a plastic hammer to
remove it.
5. REMOVE DIFFERENTIAL CASE
(a) (A540E)
Remove the differential case, outer race and shim
from the transaxle case.
AT-34- AUTOMATIC TRANSAXLERemoval of Component Parts

AT4601
A540H
AT3586
AT3587
AT3588 AT4176
A540H(A540H)
Remove the differential assembly.
(b) Remove the two apply gaskets.
6. REMOVE DRIVE PINION CAP
(a) Remove the bolt.
(b) Using pliers, pull out the drive pinion cap.
(c) Remove the O-rings from the cap.
7. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload.
Preload (at starting): Reused bearing
5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N-m)
The total preload measured in step 1 minus the drive
pinion preload equals 1.3 - 2.0 kg-cm (1.1 - 1.7 in.-lb,
0.1 - 0.2 N-m). If the result is not within this specifica-
tion, the side bearing preload is bad.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-35

r Non-reusable part

Precoated part kg-cm (ft-lb, N-m) : Specified torquer Oil Seal1,260 (91,124) Oil BaffleDifferential Pinion
LH Side Bearing RetainerAdjusting ShimOuter RaceSide
BearingRing GearSide Gear
Thrust Washer Speedometer
Drive GearDifferential Right CaseSide Bearing r Lock NutOuter RaceShim 640 (46, 63)RN Retainer Counter Driven Gearr Oil Seal
Bearing195 (14, 19)
Outer Racer Spacer
Oil SlingerSensor Rotor Snap Ringr Oil Sealr O-RingBearing
CageOuter RaceBearingDrive Pinion
Pinion Thrust WasherDifferential
Spider Differential
Side Gear Differential Left Case
Differential Assembly (A540E)
COMPONENTS
AT3674
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)AT-99

MatchmarksAT7733
AT7734
AT7735
AT7736
Matchmarks
AT7732
SST
DISASSEMBLY OF DIFFERENTIAL CASE
1. REMOVE SIDE BEARING
Using SST, remove the two side bearings.
SST 09950-20017
2. REMOVE RING GEAR
(a) Place the matchmarks on both the differential case
and ring gear.
(b) Remove the sixteen bolts.
(c) Using a plastic hammer, tap out the ring gear.
3. DISASSEMBLE OF DIFFERENTIAL CASE
(a) Place the matchmarks on the differential right and
left case.
AT-100- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)