automatic transmission 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

ABBREVIATIONS USED IN THIS MANUAL
A/T ATM Automatic Transmission
ATF Automatic Transmission Fluid
B
0 Overdrive Brake
B
1 Second Coast Brake
B
2 Second Brake
B
3 First and Reverse Brake
C
0 Overdrive Clutch
C
1 Forward Clutch
C
2 Direct Clutch
D Disc
D/F Differential
LH Left
MP Multipurpose
O/D Overdrive
P Plate
RH Right
SSM Special Service Materials
SST Special Service Tools
IN-6- INTRODUCTIONAbbreviations Used in This Manual

Illustration
09226 - 10010Part No.
Crankshaft Front &
Rear Bearing ReplacerPart Name
A540HNote
09240 - 00020
Wire Gauge Set
09308 - 00010Oil Seal PullerA540H
09316 - 12010Transfer Bearing
ReplacerA540H
09316 - 20011Transfer Bearing
Replacer
09316 - 60010Transmission &
Transfer Bearing
Replacer
(09316 - 00010)
(Replacer Pipe)
(09316 - 00040)
(Replacer ºCº)A540H
(09316 - 00060)
(Replacer ºEº)A540H
09318 - 12010Transfer Bearing
Adjusting Nut WrenchA540H
09325 - 12010Transmission Oil
PlugA540H
09325 - 20010Transmission Oil
PlugA540H
09326 - 20011Output Shaft Bearing
Lock Nut WrenchA540H
09330 - 00021Companion Flange
Holding ToolA540H
09350 - 32014TOYOTA Automatic
Transmission Tool
Set
PREPARATION
SST (SPECIAL SERVICE TOOLS)
- AUTOMATIC TRANSAXLEPreparationAT-9

Type of Transmission
A540E
A540H
Type of Engine
2VZ-FE
3S-FE
Torque ConverterStall Torque Ratio
1.9 : 1
2.0 : 1
Lock-Up Mechanism
Equipped
u
Gear Ratio1st Gear
2.810
u
2nd Gear
1.549
u
3rd Gear
1.000
u
O/D Gear
0.734
u
Reverse Gear
2.296
Number of Discs and
Plates (Disc/Plate)C
0O/D Direct Clutch
2/2
u
C
1Forward Clutch 4/4
u
C
2Direct Clutch 3/3
u
B
22nd Brake
3/3
u
B
3First & Reverse Brake 7/7 6/6
B
0O/D Brake
3/3
u
mm (in.)B1 Band Width
38 (1.50)
25 (0.98)
AT FType
ATF DEXRON
IIATF Type T or
equivalent
Capacity liter
(US qts, Imp. qts)A/T5.9 (6.2, 5.2)
7.0 (7.4, 6.2)
D/F1.0 (1.1, 0.9)
Transfer OilTypeTransaxle oil E50,
API GL5,
SAE 75W-90
or equivalent
Capacity liter (US qts, Imp. qts)
0.7 (0.7, 0.6)
General Specification
u
AT-4- AUTOMATIC TRANSAXLEDescription

NOMENCLATURE
OPERATION
Forward Clutch
C
1Connects input shaft and front planetary ring gear
Direct Clutch
C
2Connects input shaft and front & rear planetary sun gear
2nd Coast Brake
B
1Prevents front & rear planetary sun gear from turning either clockwise or counterclockwise
2nd Brake
B
2Prevents outer race of F1 from turning either clockwise or counterclockwise, thus preventing front &
rear planetary sun gear from turning counterclockwise
1st & Reverse Brake
B
3Prevents rear planetary carrier from turning either clockwise or counterclockwise
No. 1 One-Way Clutch
F
1When B2 is operating, prevents front & rear planetary sun gear from turning counterclockwise
No. 2 One-Way Clutch
F
2Prevents rear planetary carrier from turning counterclockwise
O/D Direct Clutch
C
0Connects overdrive sun gear and overdrive-planetary carrier
O/D Brake
B
0Prevents overdrive sun gear from turning either clockwise or counterclockwise
O/D One-Way Clutch
B
0When transmission is being driven by engine, connects overdrive sun gear and overdrive carrier
Planetary GearsThese gears change the route through which driving force is transmitted in accordance with the
operation of each clutch and brake in order to increase or reduce the input and output speed
AT3207
Rear Planetary CarrierFront Planetary Ring Gear OUT O/D Planetary Sun GearINInput Shaft Shaft O/D Planetary CarrierIntermediateFront Planetary Carrier Rear Planetary
Ring Gear O/D Planetary Ring Gear
and Counter Drive Gear
FUNCTION OF COMPONENTS
Front and Rear Planetary Sun Gear
AT-6- AUTOMATIC TRANSAXLEOperation

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

AT7759
AT0090
AT3576
Manual
Valve LeverParking
Lock Rod
AT3574 AT2731
Lock PawlPin
INSTALLATION OF 4-SPEED GEAR UNIT
1. INSTALL PARKING LOCK PAWL
(a) Place the parking lock pawl onto the case.
Hook the spring ends to the case and pawl.
(b) Install the pin into the hole of the case through the
spring and pawl.
2. INSTALL MANUAL VALVE SHAFT
(a) Coat the oil seal lip with the MP grease.
(b) Install the manual valve shaft oil seal to the case.
(c) Assemble a new collar to the manual valve lever.
(d) Install the manual valve shaft to the transmission
case through the manual valve lever.
(e) Install the parking lock rod.
(f) Using a pin punch, drive in the roll pin until its sur-
face is flush with the manual valve lever surface.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-129

AT5025
Retaining
Spring
AT0312
AT0969
AT2757AT0093
(g) Match the collar hole to the lever calking hollow
and calk the collar to the lever.
(h) Install the retaining spring.
3. INSTALL PARKING LOCK PAWL BRACKET
Torque: 75 kg-cm (65 in.-lb, 7.4 N-m)
4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the
manual valve lever is in the P range.
5. INSTALL FIRST AND REVERSE BRAKE PISTON TO
TRANSMISSION CASE
(a) Coat the new O-rings with ATF.
(b) Install the two O-rings on the piston.
AT-130- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3735
AT7700
AT3545
AT3736 AT3547
(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.
(f) Check the distance between the direct clutch
drum and the sun gear input drum.
Distance: Approx. 3 mm (0.12 in.)
25. INSTALL OIL PUMP INTO CASE
(a) Coat a new O-ring with ATF and install it to the oil
pump.
(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-lb, 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.)
(A 540H)
Race thickness: 0.8 mm (0.031 in.)
1.4 mm (0.055 in.)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-139

A140L Automatic Transaxle
CONSTRUCTION AND OPERATION
The A140L automatic transaxle can be roughly divided into the automatic transmission section and the
differential section. The automatic transmission section is composed of the torque converter, planetary
gear unit and the hydraulic control system.
OPERATION
The pump impeller is rotated by the engine, which
causes a flow in the ATF inside the torque converter.
The flow of ATF caused by the pump impeller strikes
the turbine runner, providing a force to rotate the tur-
bine runner, and transmits torque to the input shaft.
The flow of ATF which has hit the turbine runner re-
bounds and tries to flow in the direction opposite to
the direction of rotation of the pump impeller, but the
stator returns the flow the original direction of rotation.
So the ATF
becomes a force which supports the pump impeller
and increases torque.
HINT: Although the stator is immobilized by the one-
way clutch, should the one±way clutch become de-
fective the stator will be rotated by the flow of ATF,
the flow of
ATF will not be reversed, torque will not be increased
and the problem of inadequate acceleration will occur.
The lock±up clutch is pushed against the front cover
by fluid pressure so that the engine revolutions are
directly transmitted to the input shaft without the me-
dium of the
AT F.
1. Torque Converter
CONSTRUCTION
The torque converter is composed of the pump impeller
which is rotated by the engine, the turbine runner and
lock±up clutch which are fixed to the transmission input
shaft, and the stator which is attached to the stator
shaft via the one±way clutch.
The torque converter is filled with ATF.
± AUTOMATIC TRANSAXLEDescription (A140L and A140E)AT±5