TOYOTA CAMRY V20 1986 Service Information

(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. 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)
8. INSTALL OVERDRIVE UNIT
(a) Install the overdrive brake apply gasket and overdrive
clutch apply gasket. (c) Push the piston into the bore of the case, facing
the spring seat upward.
7. INSTALL SNAP RING TO TRANSAXLE CASE
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±393

9. CHECK INTERMEDIATE SHAFT END PLAY
(a) Make sure that the intermediate shaft has thrust plate)
in axial direction.
Thrust play: 0.47 ± 1.50 mm (0.0185 ± 0.0591 in.)
If the thrust play is not within specification, check the installa-
tion of intermediate shaft.
(See page AT±306)
(b) Make sure that the intermediate shaft turns smoothly.(g) Coat the threads of 23 mm (0.91 in.) bolts with sealer.
Sealer: Part No. 08833±00070, THREE BOND 1324
or equivalent.
(h) Install and tighten the thirteen bolts.
Torque: 250 kg±cm (18 ft±Ib, 25 N±m)
HINT: Each bolt length (mm (in.)) is indicated in the figure. (e) Place the new gasket onto the transaxle case.
M Install the overdrive assembly with overdrive
case to the transaxle case. (d) Make sure that the length from the top surface of
the case to the counter driven gear top surface
should be about 24 mm (0.94 in.) (b) Install the overdrive brake drum to the case.
(c) Install the new case gasket to the case.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±394

10. INSTALL REAR PLANETARY GEAR
(a) Install the rear planetary ring gear.
(b) (A540E)
Place the bearing onto the ring gear.
(e) (A540H)
Coat the races and bearing with petroleum jelly and
install them onto the ring gear.
Bearing and race: mm (in.)
11. INSTALL DISCS, PLATES AND FLANGE OF FIRST
AND REVERSE BRAKE
(a) Install the seven plates and seven discs.
Install in order: P = Plate D = Disc
A540E: P±D±P±D±P±D±P±D±P±D±P±D±P±D
A540H: P±D±P±D±P±D±P±D±P±D±P±D
(b) Install the flange, facing the flat end downward.
(c) Install the snap ring.
HINT: Be sure that the end gap of the snap ring is
not aligned with one of cutouts.(d) Coat the thrust washer with petroleum jelly and
place it onto the rear planetary gear.
(3) Install the rear planetary gear.
Front Race
mm (in.)
Rear Race A540HBearing
Bearing A540E
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±395

(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. (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.) 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) Install the one±way clutch while turning the planetary 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. 13. INSTALL NO. 2 ONE±WAY CLUTCH INTO CASE
(a) Place the No. 2 one±way clutch with the shiny side of
flange upward.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±396

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 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. 14. INSTALL SECOND COAST BRAKE BAND GUIDE
(c) Place the piston return spring into the case.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±397

(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.
19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
(a) Coat the thrust washer with petroleum jelly an install
it on the sun gear input drum. 18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket
and confirm that the piston moves. 17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the sec-
ond brake drum.(d) Place the second brake drum into the case.
HINT: Align the groove of the drum with the bolt.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±398

HINT: The bearings are the same on the (A) and (B)
side (A540E).
(b) Install the planetary gear onto the sun gear.
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.) 21. INSTALL FRONT PLANETARY GEAR
(a) Coat the races and bearings with petroleum jelly, and
install them onto the both sides of planetary gear. 20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT
HINT: After installing the oil seal ring, check that it
moves smoothly.(b) While turning the sun gear clockwise, install it into
the No. 1 one±way clutch.
Bearing and race:
Front Race
Rear Race Beating Bearing
Bearing Bearing
A540HA540H
A540EA540E
Race
Bearing and race: mm (in.)
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±399

(c) Coat the thrust washer with petroleum jelly an(
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. (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 bear-
ings (A540E) for adjustment of the input shaft thrust play.
Bearing: A540E 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.
Bearing and race mm (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.
Bearing and race: A540H
Outer Diameter
Outer Diameter
Outer DiameterInner Diameter
Inner Diameter Inner Diameter
Front Race
mm (in.)
Thickness Thickness
mm (in.)
Rear Race BearingBearing
BearingBearing
A540H A540E
Race
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±400

(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±Ib, 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.)
(A540H)
Race thickness: 0.8 mm (0.031 in.)(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.
25. INSTALL OIL PUMP INTO CASE
(a) Coat a new O±ring with ATF and install it to the oil
purnp.(f) Check the distance between the direct clutch
drum and the sun gear input drum.
Distance: Approx. 3mm (0.12 in.)
0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±401

(b) Using SST, measure the piston stroke applying an(
releasing the compressed air (4 ± 8 kg/cm2, 57 ±
114 psi or 392 ± 785 kPa) as shown.
SST 09240±00020
Piston stroke: 2.0 ± 3.5 mm (o.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 ban(
with a new one. 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 con-
tacts the center of the second brake band de-
pression.
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.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±402