1986 TOYOTA CAMRY V20 brake

(b) Using SST, measure the piston stroke applying
and releasing the compressed air (4 ± 8 kg/
cm2, 5 7 ± 114 psi or 392 ± 785 kPa) as shown.
SST 09240±00020
Piston stroke: 1.5 ± 3.0 mm (0.059 ± 0.118 in).
If the stroke is more than standard value, replace
the piston rod with a longer one.
Piston rod length: 72.9 mm (2.870 in)
71.4 mm (2.811 in)
41. INSTALL THROTTLE CABLE IN CASE
Push the cable through the case, being careful not to
damage the O±ring. Check for full seating.
NOTICE: In subsequent work, to avoid breaking the cable
fitting do not roll the case over the cable.
(b) Place the cover with the gasket and tighten the
bolts gradually in sequence.
HINT: Each bolt length (mm (in.)) is indicated in
the figure.
39. INSTALL NEW SECOND BRAKE APPLY GASKET
40. (A 1401.)
INSTALL NEW GOVERNOR OIL STRAINER 38. INSTALL ACCUMULATOR PISTONS AND SPRINGS
(a) Install the springs and pistons into the bore.
Free length mm (in)
None
Yellow Green Inner
Outer
Orange Spring
Yellow Color
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A140L and A140E)AT±177

( ) 1: No fail±safe function X: Malfunctions
HINT: (A540H) When any one of the speed sensors (front or rear) or center differential control sole-
noid valves (No. 1 or No. 2) malfunction, the ECT ECU stops center differential control and main-
tains the center differential in a free condition.
Operating Mechanism for Each Gear (A540E A540H)
1. CLUTCH BRAKE AND ONE±WAY CLUTCH
A540E, A540H
Down±shift only ± no up±shift
2. SOLENOID SYSTEM
Possible gear positions in accordance with solenoid operating conditions.
A540E, A540H
NO. 2 SOLENOID
MALFUNCTIONING NO. I SOLENOID
MALFUNCTIONINGBOTH SOLENOIDS
MALFUNCTIONING Shift lever
positionGear position
NORMAL
D rangeParking
2 range
L rangeReverse
Neutral
Range
2nd3 rd
O/D
2nd1st
1st 1st2nd
3rd
± AUTOMATIC TRANSAXLETroubleshooting (Operating Mechanism for Each Gear
(A540E and A540H)AT±189

Diagnosis System
DESCRIPTION
1. A self±diagnosis function is. built into the electrical control
system. Warning is indicated by the overdrive OFF indicator.
HINT: Warning and diagnostic codes can be read only when
the overdrive switch is ON. If OFF, the overdrive OFF
indicator is lit continuously and will not blink.
(a) If a malfunction occurs within the speed sensors or sole-
noids, the overdrive OFF light will blink to warn the driver.
However, there will be no warning of a malfunction with
lock±up solenoid.
W The diagnostic code can be read by the number of
blinks of the overdrive OFF indicator when terminals
Tt and E1 are short±circuited. (See page AT± 191)
(c) The throttle position sensor or brake signal are not indicated,
but inspection can be made by checking the voltage at ter-
minal Tt of the check connector.
(d) The signals to each gear can be checked by measuring the
voltage at terminal Tt of the check connector while driving.
2. The diagnostic (malfunction) code is retained in memory by the
ECU and due to back±up voltage, is not canceled out when the
engine is turned off. Consequently, after repair, it is necessary
to turn the ignition switch off and remove the fuse EFI (15A)
(A540E) or DOME (20A)
(A540H) or disconnect the Engine and ECT ECU (A540E)
or ECT ECU (A540H) connector to cancel out the diagnostic
(malfunction) code. (See page AT±192)
HINT:
wLow battery voltage will cause faulty operation of the diag-
nosis system. Therefore, always check the battery first.
wUse a voltmeter and ohmmeter that have an impedance of
at least 10 k
/V.
CHECK O/D OFF INDICATOR LIGHT
1. Turn the ignition switch ON.
2. The O/D OFF light will come on when the O/D switch
placed at OFF.
3. When the O/D switch is set to ON, the O/D OFF light should go
out.
If the O/D OFF light flashes when the O/D switch is set to
ON, the electronic control system is faulty.
± AUTOMATIC TRANSAXLETroubleshooting (Diagnosis System) (A540E and A540H)AT±190

Preliminary Check
1. CHECK TRANSAXLE FLUID LEVEL
HINT:
The vehicle must have been driven so that the engine
and transaxle are at normal operating temperature.
(Fluid temperature: 158 ± 176
°F or 70 ± 80°C)
(a) Park the vehicle on a level surface, set the parking brake.
(b) With the engine idling, shift the shift lever into all
positions from P to L position and return to P position.
HINT: Depress the brake pedal.
(e) Pull out the transaxle dipstick and wipe it clean.
(d) Push it back fully into the tube.
(e) Pull it out and check that the fluid level is in the HOT
range.
If the level is at the low side, add fluid.
Fluid type: A540E ATF DEXRON
II
A540H ATF Type T (08886±00405) or equivalent
NOTICE: Do not overfill.
2. (A540H)
CHECK TRANSFER OIL LEVEL
(a) Park the vehicle on a level surface, set the parking brake.
(b) Pull out the transfer dipstick and wipe it clean.
(e) Push it back fully into the tube.
(d) Pull it out and check the oil level as shown in the illustra-
tion.
Oil type: Transaxle oil E50 (08885±80206), AP GL5,
SAE 75W ± 90 or equivalent
NOTICE: Do not overfill.
± AUTOMATIC TRANSAXLETroubleshooting (Preliminary Check) (A540E and A540H)AT±199

Mechanical System Tests
STALL TEST
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
CAUTION:
wPerform the test at normal operation fluid temperature (122 ± 176°F or 50 ± 80°C).
wDo not continuously run this test longer than 5 seconds.
wTo ensure safety, conduct this test in a wide, clear, level area, which provides good traction.
wThe stall test should always be carried out in pairs. One should observe the conditions of wheels
or wheel stoppers outside the vehicle while the other is performing the test.
MEASURE STALL SPEED
(a) Chock the front and rear wheels.
(b) Connect a tachometer to the engine.
(c) Fully apply the parking brake.
(d) Step down strongly on the brake pedal with your left foot.
(e) Start the engine.
(f) Shift into the D range. Step all the way down on the accelerator pedal with your right foot. Quickly
read the stall speed at this time.
Stall speed: A540E (2VZ±FE) 2,450
+150 rpm
A540H (3S±FE) 2,320
+150 rpm
(g) Perform the same test in R range.
EVALUATION
(a) If the stall speed is the same for both ranges without the rear wheels rotating but lower than specified
value:
wEngine output may be insufficient
wStartor one±way clutch is not operating properly
(b) If the stall speed in D range is higher than specified:
wLine pressure too low
wForward clutch slipping
wNo. 2 one±way clutch not operating properly
wO/D one±way clutch not operating properly
(e) If the stall speed in R range is higher than specified:
wLine pressure too low
wDirect clutch slipping
wFirst and reverse brake slipping
wO/D one±way clutch not operating properly
(d) If the stall speed in both R and D ranges are higher than specified:
wLine pressure too low
wImproper fluid level
wO/D one±way clutch not operating properly
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±222

TIME LAG TEST
If the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward
clutch, direct clutch and first and reverse brake.
NOTICE: .
wPerform the test at normal operating fluid temperature (122 ± 176°F or 50 ± 80°C).
wBe sure to allow one minute interval between tests.
wMake three measurements and take the average value.
MEASURE TIME LAG
(a) Fully apply the parking brake.
(b) Start the engine and check the idle speed.
Idle speed (N range): 700 rpm (A540E and A540H)
(c) Shift the shift lever from N to D position. Using a stopwatch, measure the time it takes from shifting
the lever until the shock is felt.
Time lag: Less than 1.2 seconds.
(d) In the same manner, measure the time lag for N ± R.
Time lag: Less than 1.5 seconds.
EVALUATION
(a) If N ± D time lag is longer than specified:
wLine pressure too low
wForward clutch worn
wO/D one±way clutch not operating properly
(b) If N ± R time lag is longer than specified:
wLine pressure too low
wDirect clutch worn
wFirst and reverse brake worn
wO/D one±way clutch not operating properly
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±223

HYDRAULIC TEST
PREPARATION
(a) Warm up the transaxle fluid.
(b) Remove the transaxle case test plug and connect the hydraulic pressure gauge.
SST 09992±00094 (Oil pressure gauge)
NOTICE:
wPerform the test at normal operating fluid temperature (122 ± 176°F or 50 ± 80°C)
wThe line pressure test should always be carried out in pairs. One should observe the conditions of
wheels or wheel stoppers outside the vehicle while the other is performing the test.
MEASURE LINE PRESSURE
(a) Fully apply the parking brake and chock the four wheels.
(b) Start the engine and check idling rpm.
(c) Step down strongly on the brake pedal with your left foot and shift into D range.
(d) Measure the line pressure when the engine is idling.
(e) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine
speed reaches stall speed.
(f) In the same manner, perform the test in R range.
(A540E)
kg/cm2 (psi, kPa)
Line pressure
D rangeR range
Idling
IdlingStallStall
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±224

If the measured pressure are not up to specified values, recheck the throttle cable adjustment and
perform a retest.
EVALUATION
(a) If the measured values at all ranges are higher than specified:
wThrottle cable out of adjustment
wThrottle valve defective
wRegulator valve defective
(b) If the measured values at all ranges are lower than specified:
wThrottle cable out of adjustment
wThrottle valve defective
wRegulator valve defective
wOil pump defective
wO/D direct clutch defective
(e) If pressure is low in the D range only:
wD range circuit fluid leakage
wForward clutch defective
(d) If pressure is low in the R range only:
wR range circuit fluid leakage
wDirect clutch defective
wFirst and reverse brake defective
kg/cm2 (psi, kPa)
Line pressure
(A540H)
R rangeD
rang
e Id-
lin
g
IdlingS
t
al
l
Stall
± AUTOMATIC TRANSAXLETroubleshooting (Mechanical System Tests) (A540E and
A540H)AT±225