1986 TOYOTA CAMRY V20 differential

AT3583
A540E
AT4173
A540H
AT3584
A540E
AT3585
A540E
AT4232
A540H
4. REMOVE CARRIER COVER
(a) Remove the eleven bolts.
(b) Tap the carrier cover with a plastic hammer to
remove it.
5. REMOVE DIFFERENTIAL CASE
(a) (A540E)
Remove the differential case, outer race and shim
from the transaxle case.
AT-34- AUTOMATIC TRANSAXLERemoval of Component Parts

AT4601
A540H
AT3586
AT3587
AT3588 AT4176
A540H(A540H)
Remove the differential assembly.
(b) Remove the two apply gaskets.
6. REMOVE DRIVE PINION CAP
(a) Remove the bolt.
(b) Using pliers, pull out the drive pinion cap.
(c) Remove the O-rings from the cap.
7. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload.
Preload (at starting): Reused bearing
5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N-m)
The total preload measured in step 1 minus the drive
pinion preload equals 1.3 - 2.0 kg-cm (1.1 - 1.7 in.-lb,
0.1 - 0.2 N-m). If the result is not within this specifica-
tion, the side bearing preload is bad.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-35

r Non-reusable part

Precoated part kg-cm (ft-lb, N-m) : Specified torquer Oil Seal1,260 (91,124) Oil BaffleDifferential Pinion
LH Side Bearing RetainerAdjusting ShimOuter RaceSide
BearingRing GearSide Gear
Thrust Washer Speedometer
Drive GearDifferential Right CaseSide Bearing r Lock NutOuter RaceShim 640 (46, 63)RN Retainer Counter Driven Gearr Oil Seal
Bearing195 (14, 19)
Outer Racer Spacer
Oil SlingerSensor Rotor Snap Ringr Oil Sealr O-RingBearing
CageOuter RaceBearingDrive Pinion
Pinion Thrust WasherDifferential
Spider Differential
Side Gear Differential Left Case
Differential Assembly (A540E)
COMPONENTS
AT3674
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)AT-99

MatchmarksAT7733
AT7734
AT7735
AT7736
Matchmarks
AT7732
SST
DISASSEMBLY OF DIFFERENTIAL CASE
1. REMOVE SIDE BEARING
Using SST, remove the two side bearings.
SST 09950-20017
2. REMOVE RING GEAR
(a) Place the matchmarks on both the differential case
and ring gear.
(b) Remove the sixteen bolts.
(c) Using a plastic hammer, tap out the ring gear.
3. DISASSEMBLE OF DIFFERENTIAL CASE
(a) Place the matchmarks on the differential right and
left case.
AT-100- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)

AT7737
AT7739
AT3676
(b) Using a torx wrench, remove the sixteen torx
screws.
(c) Using a plastic hammer, tap out the differential
left case.
(d) Remove the speedometer drive gear from the
differential right case.
AT7738
(e) Remove the two differential side gears, two side
thrust washers, differential spider, four differential
pinions and four pinion washers from the differential
left case.
4. DISASSEMBLE LH BEARING RETAINER
(a) Using a hammer and screwdriver, remove the oil
seal.
(b) Remove the oil baffle from the LH bearing retainer.
AT3675
(c) Using a hammer and brass bar, drive out the outer
race and adjusting shim from LH bearing retainer.
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)AT-101

AT3678
SST
AT3679
AT3680
SST
AT7740AT3677
5. REMOVE RH OIL SEAL FROM RH RETAINER
Using a hammer and screwdriver, drive out the oil seal.
ASSEMBLY OF DIFFERENTIAL CASE
1. INSTALL RH OIL SEAL TO RH RETAINER
(a) Using SST, drive in a new oil seal until its surface
is flush with the surface of RH retainer.
SST 09316-60010 (09316-00010)
(b) Coat the oil seal lip with MP grease.
2. INSTALL ADJUSTING SHIM AND BEARING OUTER
RACE TO LH BEARING RETAINER
(a) Place the adjusting shim into the LH bearing
retainer.
HINT: Use either the shim which was removed or one
2.40 mm (0.0945 in.).
(b) Using SST, press the outer race into the LH
retainer.
SST 09316-2001 1, 09350-32014 (09351-32150)
HINT: Install the oil baffle and oil seal after adjusting the
differential side bearing preload.
(See page AT-126)
3. ASSEMBLE DIFFERENTIAL CASE
HINT: Coat all of the sliding and rotating surface with
ATF before assembly.
(a) Install the thrust washer to the side gear.
AT-102- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)

AT7742
Thicknessmm (in.)
0.80 (0.0315)
0.90 (0.0354)
1.00 (0.0394)
1.10 (0.0433)1.20 (0.0472)
1.30 (0.0512)
1.40 (0.0551)
AT7743
AT7744
Matchmarks
AT7741
(b) Install the four pinions and thrust washers to the
spider.
(c) Install the side gear and spider with four pinions to
the differential left case.
(d) Using a dial indicator, measure the backlash of one
pinion gear while holding the side gear.
Standard backlash: 0.05 - 0.20 mm
(0.0020 - 0.0079 in.)
(e) Install the side gear and spider with four pinions to
the right side of the differential case.
And check the pinion gear backlash.
(f) Referring to the table below, select the side gear
thrust washer which will ensure that the backlash
is within specification. Try to select a washer of the
same size.
(g) Install the speedometer driven gear.
(h) Align the matchmarks on the differential cases.
- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)AT-103

AT7746
AT7747
AT7748
Speedometer
Driven Gear
Side
AT3681
SST
AT7745
(i) Using a plastic hammer, carefully tap the differential
right case.
(j) Using a torx wrench, install and torque the sixteen
torx screws.
Torque: 640 kg-cm (46 ft-lb, 63 N-m)
4. INSTALL RING GEAR
(a) Clean the contact surface of the differential case.
(b) Heat the ring gear to about 212°F (100°C) in an
oil bath.
NOTICE: Do not heat the ring gear above 230°F
(110°C).
(c) Clean the contact surface of the ring gear with
cleaning solvent.
(d) Quickly install the ring gear on the differential case.
Install the sixteen bolts.
HINT: Align the matchmarks on the differential left case
and contact the ring gear.
(e) Tighten the set bolts uniformly and a little at a time.
Torque the bolts.
Torque: 1,260 kg-cm (91 ft-lb, 124 N-m)
5. INSTALL SIDE BEARINGS
(a) Using SST and a press, install the RH side bearing
to the differential case.
SST 09361-2001 1
AT-104- AUTOMATIC TRANSAXLEComponent Parts (Differential Assembly-A540E)