Air TOYOTA CAMRY V20 1986 Service Information

Pub. NamePub. No.
'91 Camry Repair ManualRM199U Automatic TransmissionApplicable Model
A540E
A540H'91 Camry
FOREWORD
This repair manual covers Disassembly, Inspection and As-
sembly procedures for the following Automatic Transaxles:
For On-vehicle Servicing (Inspection, Adjustment, Trouble-
shooting, Removal and Installation) of Automatic Transaxle,
refer to the repair manual for the applicable vehicle model.
All information contained in this manual is the most up-to-data
at the time of publication. However, specifications and proce-
dures are subject to change without notice.
TOYOTA MOTOR CORPORATION

HOW TO USE THIS MANUAL
To assist you in finding your way through the manual, the
Section Title and major heading are given at the top of every
page.
An INDEX is provided on the 1st page of each section to
guide you to the item to be repaired.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration.
It identifies the components and shows how the parts fit
together.
Example:
kg-cm (ft-lb, N-m)
AT3608r Non-reusable part
: Specified torque
r O-Ring r Oil SealDrive GearThrust WasherOil Seal Ring Pump BodyDriven GearStator Shaft100 (7, 10)
IN-2- INTRODUCTIONHow to Use This Manual

Illustration:
what to do and where
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task head-
ing can be read at a glance and only when necessary, the text
below it provides detailed information. Important specifications
and warnings always stand out in bold type.SST 09350-32014 (09351-32190) If replacing the disc, plate or flange, check the piston
stroke:
Set part No.
Piston stroke: 1.41 - 1.82 mm (0.0555 - 0.0717 in.) The procedures are presented in a step-by-step format:

Illustration shows what to do and where to do it.

The task heading tells what to do.

The detailed text tells how to perform the task and
gives other information such as specifications and
warnings.
Example:
Task heading: what to do
7. CHECK PISTON STROKE OF FORWARD CLUTCH
Detail text: how to do it
Using a dial indicator (long type pick or SST), measure
the forward clutch piston stroke applying and releasing
the compressed air (4 - 8 kg/cm
2, 57 - 114 psi or 392
- 785 kPa) as shown.
Component part No.
Specification
REFERENCES
References have been kept to a minimum. However, when
they are required you are given the
page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A, specifications for quick reference.
CAUTIONS, NOTICES, HINTS:

CAUTIONS are presented in bold type, and indicate
there is a possibility of injury to you or other people.

NOTICES are also presented in bold type, and indicate
the possibility of damage to the components being re-
paired.

HINTS are separated from the text but do not appear in
bold. They provide additional information to help you effi-
ciently perform the repair.
- INTRODUCTIONHow to Use This ManualIN-3

IN0036
Seal Lock Adhesive
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in order to facilitate
reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative cable four the battery terminal.
(b) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the cable from
the negative (-) terminal which is grounded to the
vehicle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight
up without twisting it or prying it.
(d) Clean the battery terminal posts and cable termi-
nals with a shop rag. Do not scrape them with a file
or other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer or such to tap the terminal onto
the post.
(f) Be sure the cover for the positive (+) terminals are
properly in place.
4. Check hoses and wiring connectors to make sure
that they are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, O-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the ºrº symbol.
6. Precoated parts
Precoated parts are the bolts and nuts, which have
been coated with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated
with the specified adhesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut
or installation part threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
(c) Precoated parts are indicated in the component il-
lustrations by the º
º symbol.
IN-4- INTRODUCTIONGeneral Repair Instructions

7. When necessary, use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tighten-
ing torques. Always use a torque wrench.
9. Use of special service tools (SST) and special ser-
vice materials (SSM) may be required, depending on
the nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. A list of SST and SSM can be found at the back
of this manual.
10. When replacing fuses, be sure the new fuse has the
correct amperage rating. DO NOT exceed the fuse
amp rating or use one of a lower rating.
11. Care must be taken when jacking up and supporting
the vehicle. Be sure to lift and support the vehicle at
the proper locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any
work on the vehicle raised on jack alone, even for a
small job that can be finished quickly.
- INTRODUCTIONGeneral Repair InstructionsIN-5

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

COMPONENT PARTS
General Notes
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-looking parts of different subassemblies being on
your workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the
next component group. If a component group can not be assembled because parts are being or-
dered, be sure to keep all parts of that group in a separate container while proceeding with disas-
sembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: A540E ATF DEXRON
II
A540H ATF Type T or equivalent
Recommended oil for the transfer: Transaxle oil E50, API GL5, SAE 75W-90 or equivalent
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean, with any fluid passages and holes blown
through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent acciden-
tally spraying automatic transaxle fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection,
repairs, and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corre-
sponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle
fluid for at least fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are
installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be re-
placed.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
- AUTOMATIC TRANSAXLEComponent Parts (General Notes)AT-39

AT3538
AT3539
AT3599
Piston O-ring
AT3541 AT3540
20. REMOVE THROTTLE CABLE AND SOLENOID WIRE
21. REMOVE ACCUMULATOR PISTONS AND SPRINGS
(a) Loosen the five bolts one turn at a time until the
spring tension is released.
(b) Remove the cover and gasket.
(c) Remove the C
1 accumulator piston.
(d) Remove the O-ring.
(e) Pop out pistons for C
2 and B2 into a rag, using
low-pressure compressed air (1 kg/cm2, 14 psi
or 98 kPa). Force air into the holes shown and
remove the pistons and springs.
(f) Remove the O-rings from the pistons.
22. MEASURE PISTON STROKE OF SECOND COAST
BRAKE
(a) Apply a small amount of paint to the piston rod
at the point it meets the case as shown in the
illustration.
AT-22- AUTOMATIC TRANSAXLERemoval of Component Parts

AT3543
SST
AT3544
Cover Piston
AT3545
AT3546
SST
AT3542
(b) Using SST, measure the piston stroke applying and
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 (0.079 - 0.138 in.)
If the piston stroke exceeds the limit, inspect the second
coast brake band (See page AT-41).
23. REMOVE SECOND COAST BRAKE PISTON
(a) Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)
(b) Remove the cover.
(c) Remove the piston and outer return spring.
(d) Remove the two O-rings from the cover.
24. STAND TRANSAXLE ENGINE SIDE UPWARD
25. REMOVE OIL PUMP
NOTICE: Before removing the oil pump, remove the
second coast brake piston.
(a) Remove the seven bolts.
(b) Using SST, pull out the oil pump from the transaxle
case.
SST 09350-32014 (09351-32061)
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-23

AT3601
AT3554
AT3555
AT3556AT0132
34. CHECK OPERATION OF SECOND BRAKE PISTON
Apply compressed air into the case passage and con-
firm that the piston moves.
If the piston does not move, disassemble and inspect.
35. REMOVE SECOND COAST BRAKE BAND GUIDE
36. REMOVE SECOND BRAKE DRUM
(a) Remove the snap ring.
(b) Remove the second brake drum.
37. REMOVE SECOND BRAKE PISTON RETURN
SPRING
AT-26- AUTOMATIC TRANSAXLERemoval of Component Parts