Air TOYOTA CAMRY V20 1986 Service Information

AT7716
AT2742AT3630
r Non-reusable partr Second Brake
Drum GasketPistonPiston Return
SpringSee page AT-135 Snap RingSecond Brake
Drumr O-RingPlateDiscFlange
Second Brake
COMPONENTS
DISASSEMBLY OF SECOND BRAKE PISTON
REMOVE SECOND BRAKE PISTON
(a) Apply compressed air to the oil hole to remove
the piston.
(b) Remove the two o-rings from the piston.
- AUTOMATIC TRANSAXLEComponent Parts (Second Brake)AT-61

AT3063
AT2523
AT7719
AT7720
Printed
Numbers
AT2745
DISASSEMBLY OF OVERDRIVE BRAKE
1. REMOVE PISTON RETURN SPRING
(a) While pushing the return spring, remove the snap
ring with a screwdriver.
(b) Remove the piston return spring.
2. REMOVE PLATES, DISCS AND FLANGE
3. REMOVE PISTON FROM DRUM
Apply compressed air to oil hole to remove the piston.
HINT: Blow with the gun slightly away from the oil hole,
and be careful that the piston dose not tilt.
4. REMOVE O-RINGS
Remove the inner and outer O-rings from the piston.
INSPECTION OF OVERDRIVE BRAKE
INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is exfoliated or discolored,
or even a part of the printed numbers are defaced,
replace all discs.

Before assembling new discs, soak them in ATF
for at least fifteen minutes.
AT-68- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)

AT7721
AT7722
AT7723
AT7724 AT3634
SST
DISASSEMBLY OF OVERDRIVE DIRECT
CLUTCH
1. CHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while
applying and releasing the compressed air (4 - 8 kg/
cm
2, 57 - 114 psi or 392 - 785 kPa) as shown.
Piston stroke: 1.75 - 2.49 mm
(0.0689 - 0.0980 in.)
SST 09350-32014 (09351-32190)
If the piston stroke is greater than the maximum, inspect
each component.
2. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE
3. REMOVE BEARING AND RACE FROM CLUTCH
DRUM AND CASE
4. REMOVE SNAP RING WITH SCREWDRIVER
5. REMOVE FLANGES, DISCS AND PLATES
- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)AT-69

AT3636
AT3637
AT3638
AT3639 AT3640AT3635
SST
6. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress
the spring with a shop press.
SST 09350-32014 (09351-32070, 09351-32200)
(b) Remove the snap ring.
(c) Remove the piston return spring.
7. REMOVE PISTON FROM CLUTCH DRUM
(a) Install the clutch drum on the case.
(b) Apply compressed air to the pressure apply hole
of the case.
(c) Remove the piston from the clutch drum.
If the piston does not come out completely, use
needle-nose pliers to remove it.
(d) Remove the clutch drum from the case.
8. REMOVE O-RINGS
Remove the two O-rings from the piston.
INSPECTION OF OVERDRIVE DIRECT CLUTCH
1. INSPECT OVERDRIVE DIRECT CLUTCH
(a) Check that the check ball is free by shaking the
piston.
(b) Check that the valve does not leak by applying
low-pressure compressed air.
AT-70- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)

AT3634
SST
AT3645
HoldLockFreeTurn
AT3646
AT3751AT7721
6. INSTALL DIRECT CLUTCH ON CASE
7. RECHECK PISTON STROKE OF DIRECT CLUTCH
Using a dial indicator, measure the piston stroke while
applying and releasing the compressed air (4 - 8 kg/
cm
2, 57 - 114 psi or 392 - 785 kPa) as shown.
Piston stroke: 1.75 - 2.49 mm
(0.0689 - 0.0980 in.)
SST 09350-32014 (09351-32190)
DISASSEMBLY OF COUNTER DRIVE GEAR
1. CHECK OPERATION OF ONE-WAY CLUTCH
(a) Install the overdrive direct clutch into the one-way
clutch.
(b) Hold the overdrive direct clutch and turn the inter-
mediate shaft. The shaft should turn freely clock-
wise and should lock counterclockwise.
(c) Remove the overdrive direct clutch.
2. CHECK COUNTER DRIVE GEAR PRELOAD
(a) Hold the overdrive planetary gear in a vise with
soft jaws.
HINT: Do not let the counter drive gear touch the vise.
(b) Using a tension gauge, measure the preload.
Preload (at starting): 940 - 1,560 g
(2.1 - 3.4 lb, 9.2 - 15.3 N)
HINT: Turn the counter drive gear right and left several
times before measuring the preload.
- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)AT-73

AT3465
AT3467
AT3468
Plate GasketOil Strainer
AT3469AT3464
Check Ball B
0 Accumulator
2. REMOVE B0 ACCUMULATOR ASSEMBLY
(a) Remove the three bolts.
(b) Remove the B
0 accumulator assembly.
(c) Remove the check ball on No. 1 plate.
3. DISASSEMBLE B
0 ACCUMULATOR ASSEMBLY
(a) Applying compressed air to the cylinder hole,
remove the piston and spring.
(b) Remove the two O-ring from the piston.
4. REMOVE UPPER VALVE BODY COVER
Remove the eleven bolts and upper valve body cover.
5. REMOVE OIL STRAINER, UPPER VALVE BODY
COVER GASKETS AND PLATE
(a) Remove the oil strainer on the gasket.
(b) Remove the two gaskets and plate from the upper
valve body.
6. REMOVE LOCK-UP RELAY VALVE SLEEVE STOPPER
AT-86- AUTOMATIC TRANSAXLEComponent Parts (Valve Body)

AT4336
AT4370
AT4315 AT4314
9. REMOVE FRONT DIFFERENTIAL LEFT CASE
(a) Using a torx wrench, remove the sixteen screws
from the left case.
(b) Separate the left case and right case.
NOTICE: Do not scratch the contact surface of the
needle bearing.
10. REMOVE DIFFERENTIAL PINIONS AND SIDE GEARS
Remove the two differential side gears, two side thrust
washers, differential spider, four differential pinions and
four pinion washers from the front differential cases.
11. REMOVE NO. 1 THRUST WASHER
12. CHECK OPERATION OF CLUTCH PISTONS
(a) Plug one hole of the right case with your hand.
(b) Apply compressed air into the other hole and
confirm that the pistons move.
AT4320
13. REMOVE HYDRAULIC MULTIPLATE CLUTCH
DISCS AND PLATES
(a) Using a screwdriver, remove the snap ring.
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)AT-109

AT4316
AT4319
AT4564
AT7749
SST
AT4311
(b) Remove the flange, eleven discs and eleven plates.
(c) Place SST, and compress the return spring.
SST 09350-32014 (09351-32070)
(d) Using snap ring pliers, remove the snap ring.
(e) Apply compressed air to the right case hole to
remove the No. 1 piston.
(f) Remove the O-ring from the No. 1 piston.
(g) Using a small screwdriver, remove the reaction
sleeve and No. 2 piston.
(h) Remove the three O-rings from the reaction
sleeve and No. 2 piston.
REPLACEMENT OF RING GEAR MOUNTING
CASE BEARINGS
1. REMOVE RING GEAR MOUNTING LEFT CASE
BEARING
Using SST, remove the bearing.
SST 09950-00020, 09950-00030
AT-1 10- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)

AT7755
AT4320
AT4314
AT4671 AT4602
(c) Using a screwdriver, install the snap ring.
4. CHECK OPERATION OF CLUTCH PISTONS
(a) Plug one hole with your hand.
(b) Apply compressed air into the other hole and
make sure that the pistons move.
5. INSTALL NO. 1 THRUST WASHER
6. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE
GEAR BACKLASH
(Front Differential Left Case)
(a) Install the following parts:
 Side gear thrust washer
 Side gear
 Four differential pinion gears
 Four pinion gear thrust washers
 Differential spider
(b) Using a dial indicator, measure the backlash of
one pinion gear while holding the side gear to-
ward the case.
Backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If not within specification select the side gear thrust
washer.
NOTICE: Do not tighten the vise too tight.
(c) Remove four pinion gears, four thrust washers
and spider.
AT-1 14- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E, A540H)

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