differential TOYOTA CAMRY V20 1986 Service Information

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

IllustrationPart No.Part NameNote
09502 - 12010Differential Bearing
ReplacerA540H
09506 - 35010Differential Drive
Pinion Rear Bearing
ReplacerA540H
09520 - 32012Differential Side Gear
Shaft PullerA540H
09608 - 30022Front Hub Bearing
Replacer SetA540H
(09550 - 00050)
(Replacer)A540H
(09608 - 05010)
(Handle)A540H
09608 - 32010Steering Knuckle
Oil Seal ReplacerA540H
09608 - 35014Axle Hub & Drive
Pinion Bearing
Tool SetA540H
(09608 - 06020)
(Handle)A540H
(09608 - 06120)Front Hub Outer
Bearing Cup ReplacerA540H
09612 - 65014Steering Worm
Bearing PullerRemove pinion shaft Bearing outer race
09950 - 00020
Bearing RemoverA540H
09950 - 00030Bearing Remover
AttachmentA540H
09950 - 20017
Universal Puller
SST (SPECIAL SERVICE TOOLS) (Cont'd)
- AUTOMATIC TRANSAXLEPreparationAT-1 1

Illustration
Part No. Part Name
Note
09031 - 00030
Pin Punch
Part Name
Note
Feeler gauge
Check major clearance.
Vernier caliper with depth gauge
Check length of second coast brake piston rod.
Dial indicator with magnetic base
Check piston stroke and end play of the output shaft.
Dial indicator Check inside diameter of major bushing.
Straight edge Check side clearance of oil pump.
Torque wrenchPart Name Part No. Use etc.
Seal packing 1281,
Three bond 1281 or equivalent08826 - 00090Transfer right case y Transfer left case (A540H)
Transfer inspection hole cover (A540H)
Transfer case y Differential carrier cover
Differential LH bearing retainer (A540E, A540H)
Differential RH retainer (A540E)
Transaxle y Transfer assembly (A540H)
Adhesive 1324,
Three bond 1324 or equivalent08833 - 00070Differential LH bearing retainer set bolt
Differential carrier cover set bolt
Torque converter mounting bolt
Differential RH retainer set bolt (A540E)
Transfer set bolt (A540H)
SSM (SPECIAL SERVICE MATERIALS)
RECOMMENDED TOOL
EQUIPMENT
AT-12- AUTOMATIC TRANSAXLEPreparation

Accumulator
spring
SpringFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
Inner
Outer C
143.4 (1.709)
71.2 (2.803)17.8 (0.701)
24.4 (0.961)9.0
11.5Light Green
Blue
C
251.0 (2.008)
18.0 (0.709)
10.2
Red
C
0
(O/D case)Inner
Outer47.5 (1.870)
59.3 (2.335)18.9 (0.744)
25.5 (1.004)9.5
9.5White
Gray
B
258.5 (2.303)
15.2 (0.598)
15.9
Orange
B
0 (Valve body)
62.2 (2.449)
14.8 (0.583)
17.0
None
Differential
Side bearing adjusting shim thickness Drive pinion preload (at starting)
New Bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H0.0787 in.
0.0807 in.
0.0827 in.
0.0846 in.
0.0866 in.
0.0886 in.
0.0906 in.
0.0925 in.
0.0945 in.
0.0965 in.
0.0984 in.
0.1004 in.
0.1024 in.
0.1043 in.
0.1063 in.
0.1083 in.
0.1103 in.
0.1122 in. 2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
2.25 mm
2.30 mm
2.35 mm
2.40 mm
2.45 mm
2.50 mm
2.55 mm
2.60 mm
2.65 mm
2.70 mm
2.75 mm
2.80 mm
2.85 mm 10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m
5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m
Add drive pinion preload
2.8 - 4.4 kg-cm 2.4 - 3.8 in.-lb 0.3 - 0.4 N-m
1.4 - 2.2 kg-cm 1.2 - 1.9 in.-lb 0.1 - 0.2 N -
0.05 - 0.20 mm 0.0020 - 0.0079 in.
0.80 mm 0.0315 in.
0.90 mm 0.0354 in.
1.00 mm 0.0394 in.
1.10 mm 0.0433 in.
1.20 mm 0.0472 in.
1.30 mm 0.0512 in.
1.40 mm 0.0551 in.
Specifications (Cont'd)
A-4- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Second
coast brakeSame the A540E automatic transaxle (See page A-2)
Oil pump=
Direct clutch Piston stroke
Drum bushing inside diameter Maximum
Flange thickness1.11 - 1.47 mm
48.27 mm
2.70 mm
3.00 mm0.0437 - 0.0579 in.
1.9004 in.
0.1063 in.
0.1181 in.
Forward
clutchSame the A540E automatic transaxle (See page A-2)
Front
planetary gear=
Rear
planetary gear=
First and
reverse brakePack clearance 0.0409 - 0.0850 in.1.04 - 2.16 mm
Over drive
unitSame the A540E automatic transaxle (See page A-2)
Valve body
springSame the A540E automatic transaxle (See page A-3)
Valve body
retainerSame the A540E automatic transaxle (See page A-3)
Accumulator
springSame the A540E automatic transaxle (See page A-4) Part tightenedkg-cmft-lbN-m
Oil cooler pipe union
Oil pan
Valve body y Transaxle case
Accumulator y Cover
Oil pump y Transaxle case
O/D case y Transaxle case
Differential LH side bearing retainer
Differential RH retainer
Differential carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Differential left case y Right case
Ring gear y Differential case275
50
11 0
100
225
250
195
195
400
100
67
640
1,26027
4.9
11
10
22
25
19
19
39
10
6.6
63
124 20
43 in.-lb
8
7
16
18
14
14
29
7
58 in.-lb
46
91
Torque Specifications
AUTOMATIC TRANSAXLE (A540H)
Specifications
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-5

TransferDriven pinion preload (at starting)
Total preload (at starting)
Ring gear backlash
Driven pinion bearing cage
Driven pinion preload (at starting)
New bearing
Reused bearing
Center differential side gear backlash0.9 - 1.4 kg 2.0 - 3.1 lb 8.8 - 13.7 N
0.5 - 0.9 kg 1.1 - 2.0 lb 4.9 - 8.8 N
0.13 - 0.18 mm 0.0051 - 0.0071 in.
1.8 - 2.9 kg 4.0 - 6.4 lb 18 - 28 N
0.9 - 1.4 kg 2.0 - 3.1 lb 9 - 13 N
0.05 - 0.20 mm 0.0020 - 0.0079 DifferentialDrive pinion preload (at staring)
New bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
A
B
C
D
E
F
G
Side bearing adjusting shim thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
Differential end play2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
2.25 mm
2.30 mm
2.35 mm
2.40 mm
2.45 mm
2.50 mm
2.55 mm
2.60 mm
2.65 mm
2.70 mm
2.75 mm
2.80 mm
2.85 mm
0.18 - 0.82 mm0.0787 in.
0.0807 in.
0.0827 in.
0.0846 in.
0.0866 in.
0.0886 in.
0.0906 in.
0.0925 in.
0.0945 in.
0.0965 in.
0.0984 in.
0.1004 in.
0.1024 in.
0.1043 in.
0.1063 in.
0.1083 in.
0.1103 in.
0.1122 in.
0.0071 - 0.0323 in. 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm 10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m
5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m
2.3 - 3.7 kg-cm 2.0 - 3.2 in.-lb 0.2 - 0.4 N-m
1.2 - 1.9 kg-cm 1.0 - 1.6 in.-lb 0.1 - 0.2 N-m
0.05 - 0.20 mm 0.0020 - 0.0079 in.
Specifications (Cont'd)
TRANSFER (A540H)
Specifications
A-6- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

Transfer
(Cont'd)Center differential left side gear
thrust washer thickness
Center differential side gear
thrust clearance
Center differential right side gear
thrust washer thickness 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0071 - 0.0248 in.
0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0571 in.
0.0591 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
0.18 - 0.63 mm
1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
1.45 mm
1.50 mm
Transfer lower valve body springFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve32.2 (1.272)
28.9 (1.138)
28.9 (1.138)7.6 (0.299)
7.0 (0.276)
7.0 (0.276)16
14
14None
None
None
Transfer lower valve body retainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve6.5 (0.256)
=
=5.0 (0.197)
=
=3.2 (0.126)
=
=
Center differential plate washer
2.13 mm
2.16 mm
2.19 mm
2.22 mm
2.25 mm
2.28 mm
2.31 mm
2.34 mm
2.37 mm
2.40 mm0.0839 in.
0.0850 in.
0.0862 in.
0.0874 in.
0.0886 in.
0.0898 in.
0.0909 in.
0.0921 in.
0.0933 in.
0.0945 in.
Specifications (Cont'd)
Mark
A
B
C
D
E
F
G
H
J
Mark
A
B
C
D
E
F
G
H
J
K
L
Mark
71
72
73
74
75
76
77
78
79
80
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-7

Part tightenedkg-cmft-lb N-m
Oil cooler pipe union and elbow
Oil pan
Valve body y Transaxle case
Accumulator y Cover
Oil pump y Transaxle case
O/D case y Transaxle case
Differential LH side bearing retainer
Differential carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Front differential right case y Front differential left case
Ring gear y Ring gear mounting case
Transfer right case retainer y Transfer right case
Transfer right case y Adjusting nut lock plate lock bolt
Transfer right case y Transfer left case
Transfer right case y Mode select lever and rod275
50
11 0
100
225
250
195
400
100
67
340
1,260
300
73
450
55
11 520
43 in.-lb
8
7
16
18
14
29
7
58 in.-lb
25
91
22
63 in.-lb
33
48 in.-lb
827
4.9
11
10
22
25
19
39
10
6.6
33
124
29
7.2
44
5.4
11 Transfer
(Cont'd)81
82
83
84
85
86
87
88
89
90
91
92
93
94
Mark
A
B
C
D
E
F
G
H
J
K Ring gear adjusting shim2.43 mm
2.46 mm
2.49 mm
2.52 mm
2.55 mm
2.58 mm
2.61 mm
2.64 mm
2.67 mm
2.70 mm
2.73 mm
2.76 mm
2.79 mm
2.82 mm
0.30 mm
0.33 mm
0.36 mm
0.39 mm
0.42 mm
0.45 mm
0.48 mm
0.51 mm
0.54 mm
0.57 mm0.0957 in.
0.0969 in.
0.0980 in.
0.0992 in.
0.1004 in.
0.1016 in.
0.1028 in.
0.1039 in.
0.1051 in.
0.1063 in.
0.1075 in.
0.1087 in.
0.1098 in.
0.1110 in.
0.0118 in.
0.0130 in.
0.0142 in.
0.0154 in.
0.0165 in.
0.0177 in.
0.0189 in.
0.0201 in.
0.0213 in.
0.0224 in.
Specifications (Cont'd)
Torque Specifications
A-8- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)

ItemCapacity
Classification
Liters US qts
Imp. qts
Automatic
transaxle fluid
(w/o Differential
oil)A540E
Dry fill
Drain and refill5.9
2.56.2
2.65.2
2.2ATF DEXRON
II
A54H
Dry fill
Drain and refill7.0
3.37.4
3.56.2
2.9ATF type T (08886 - 00405) or equivalent
Differential oil
(w/ Automatic transaxle)
SV21 series
VZV21 series1.6
1.01.7
1.11.4
0.9ATF DEXRON
II
Transfer oil (A540H)
0.7
0.74 0.62
Recommended oil
Oil grade: API GL-5
Viscosity: SAE 75W-90 or 80W-90
SAE 90W
[above -18°C (0°F)]
SAE 80W
[below -18°C (0°F)]
Transaxle oil E50 (08885 - 80206) or
equivalent
Part tightenedkg-cm ft-lbN-m
Transfer right case y Oil strainer
Transfer left case y Rear wheel speed sensor
Transfer left case y Transfer inspection hole cover
Transfer left case y Drain plug
Transfer left case y Driven pinion bearing cage
Driven pinion bearing cage y Transfer extension housing
Transfer extension housing y Dynamic damper
Transfer right case y Oil pump cover
Transfer ring gear y Ring gear mounting case
Center differential control solenoid y Transfer valve body
Transfer valve body y Transfer left case
Neutral start switch bolt
Neutral start switch nut
Transfer assembly y Transaxle case48 in.-lb
48 in.-lb
12
29
29
19
19
69 in.-lb
71
10
8
48 in.-lb
61 in.-lb
51 55
55
160
400
400
260
260
80
985
145
11 0
55
70
7005.4
5.4
16
39
39
25
25
7.8
97
14
11
5.4
6.9
69
Torque Specifications (Cont'd)
LUBRICANT
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-9

AT3754
Electronic Control
SystemDifferential Hydraulic Control
SystemTorque
ConverterLock-up
Clutch 4-speed Planetary
Gear Unit
Sectional View
DESCRIPTION
GENERAL
(A540E)
The A540E is a 4-speed, Electronic Controlled Transaxle (hereafter called ECT) developed exclusively
for use with a transversely-mounted engine. A lock-up is built into the torque converter.
The A540E transaxle is mainly composed of the torque converter, the 4-speed planetary gear unit, the
differential, the hydraulic control system and the electronic control system.
AT-2- AUTOMATIC TRANSAXLEDescription