clutch TOYOTA CAMRY V20 1986 Service Information

AT3645HoldLockFreeTurn
AT0426
AT3649
AT3748
AT3647
11. INSTALL OVERDRIVE ONE-WAY CLUTCH AND
RETAINING PLATE
(a) Install the one-way clutch into the outer race.
(b) Install the two retainer on both sides of the one-
way clutch.
(c) Install the one-way clutch into the overdrive plane-
tary gear.
HINT: Be sure that the one-way clutch is installed in the
correct direction.
(d) Install the retaining plate.
(e) Install the snap ring.
12. CHECK OPERATION OF O/D ONE-WAY CLUTCH
(a) Install the overdrive direct clutch into the one-
way clutch.
(b) Hold the overdrive direct clutch and turn the in-
termediate shaft. The shaft should turn freely
clockwise and should lock counterclockwise.
(c) Remove the overdrive direct clutch.
AT-80- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)

AT1905
AT2823
AT7730
AT3673 AT3672
FlangeDisc Plate
2. INSTALL FLANGE, DISCS AND PLATES
(a) Install the flange, discs and plates.
Install in order: P = Plate D = Disc
Flange-D-P-D-P-D-P
(b) Install the cushion plate with the rounded end
facing upward.
3. POSITION PISTON RETURN SPRING
4. INSTALL SNAP RING INTO CASE
Be sure the end gap of the snap ring is not aligned with
one of cutouts.
5. INSTALL OVERDRIVE PLANETARY GEAR ONTO
OVERDRIVE DIRECT CLUTCH
While turning the overdrive planetary gear clockwise,
install it onto the overdrive direct clutch.
- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)AT-83

AT7731
HINT: If the overdrive planetary gear is properly installed
onto the direct clutch, the counter drive gear height from
the overdrive case will be about 24 mm (0.94 in.).
AT-84- AUTOMATIC TRANSAXLEComponent Parts (Overdrive Unit)

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

AT3679
AT3680
SST
AT4575Printed Number
AT3676
(c) Using a hammer and brass bar, drive out the outer
race and adjusting shim from LH bearing retainer.
6. INSTALL ADJUSTING SHIM AND BEARING OUTER
RACE TO LH BEARING RETAINER
(a) Place the adjusting shim into the LH bearing
retainer.
HINT: Use either the shim which was removed or one
2.40 mm (0.0945 in.).
(b) Using SST, press the outer race into the LH
retainer.
SST 09316-2001 1, 09350-32014 (09351-32150)
HINT: Install the oil baffle and oil seal after adjusting
the differential side bearing preload.
(See page AT-126)
INSPECTION OF HYDRAULIC MULTIPLATE
CLUTCH
INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of 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 number is defaced,
replace all discs.

Before assembling new discs, soak them in ATF
for at least fifteen minutes.
AT-1 12- 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)

AT4429
AT4317
AT7756
Oil
Bath 212°F (100°C)
AT4297
Matchmark
AT4337Matchmark
8. INSTALL FRONT DIFFERENTIAL CASE
(a) Install the front differential case to the ring gear
mounting right case.
HINT: Align the flukes of the discs in the hydraulic multi-
plate clutch.
(b) Install the No. 2 thrust washer.
9. INSTALL RING GEAR
(a) Clean the contact surface of the ring gear mounting
left case.
(b) Heat the ring gear to about 212°F (100°C) in an oil
bath.
NOTICE: Do not heat the ring gear above 230°F (110°C).
(c) Clean the contact surface of the ring gear with
cleaning solvent.
(d) Quickly install the ring gear on the ring gear mount-
ing left case.
HINT: Align the matchmarks on the ring gear mounting
left case and the ring gear.
(e) Install the ring gear and ring gear mounting left
case on the ring gear mounting right case. Install
the twelve bolts.
HINT: Align the matchmarks on the ring gear mounting
left case and contact the right case.
(f) Tighten the set bolts uniformly and a little at a time.
Torque the bolts.
Torque: 1,260 kg-cm (91 ft-lb, 124 N-m)
AT-1 16- 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

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

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