1986 TOYOTA CAMRY V20 length

AT3738
Tube
AT3534RetainerClamp
AT3739
AT4506
Only
A540H
AT4489
(c) Install and tighten the ten bolts.
HINT:
Each bolt length (mm, in.) is indicated in the figure.
Hand tighten the ten bolts first, then torque with a
torque wrench.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
34. INSTALL B
3 APPLY TUBE
NOTICE: Be careful not to bend or damage the tube.
35. INSTALL CONNECTOR CLAMP AND TUBE RETAINER
HINT: Each bolt length (mm, in.) is indicated in the figure.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
36. CONNECT SOLENOID CONNECTORS
37. INSTALL OIL TUBES
(A540E)
Using a plastic hammer, install the tubes into the posi-
tions indicated in the figure.
(A540H)
(a) Using a plastic hammer, install the tubes into the
positions indicated in the figure.
(b) Install the bolt.
Torque: 55 kg-cm (48 in.-lb, 5.4 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
NOTICE: Be careful not no bend or damage the tubes.
AT-142- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT5049
AT3532
AT3741
AT3742 AT3757
38. INSTALL MANUAL VALVE BODY AND DETENT
SPRING
HINT: Each bolt length (mm, in.) is indicated in the figure.
(a) Align the manual valve with the pin on the manual
shaft lever.
(b) Lower the manual valve body into place.
(c) Hand tighten the five bolts first. Then, tighten them
with a torque wrench.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
(d) Place the detent springs on the manual valve body
and hand tighten the two bolts first.
Then, tighten them with a torque wrench.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
(e) Check that the manual valve lever is touching the
center of the detent spring tip roller.
39. INSTALL TUBE BRACKET AND OIL STRAINER
Each bolt length (mm, in.) is indicated in the figure.
Torque:
Tube bracket 100 kg-cm (7 ft-lb, 10 N-m)
Oil strainer 110 kg-cm (8 ft-lb, 11 N-m)
40. INSTALL MAGNETS IN PLACE AS SHOWN
NOTICE: Make sure that the magnets do not interfere
with the oil tubes.
41. INSTALL OIL PAN WITH NEW GASKET
Torque: 50 kg-cm (43 in.-lb, 4.9 N-m)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-143

AT3527
Elbow UnionA540H
AT3745
AT4223
Intermediate Shaft A540H
AT7763
A540H
AT3744Manual Shift Lever
47. INSTALL MANUAL SHIFT LEVER
48. INSTALL UNION AND ELBOW
(a) Install the new O-rings to the union and elbow.
(b) Install the union and elbow to the transaxle case.
Torque: 275 kg-cm (20 ft-lb, 27 N-m)
HINT: Install the elbow at right angles to the bottom of
the transaxle case.
49. (A540H)
INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE
SHAFT
(a) Install a new snap ring to the shaft groove.
(b) Using a plastic hammer, install the shaft.
HINT: Keeping the intermediate shaft on the pinion shaft
of differential, measure the point in the illustration.
Protrusion length (Reference): 255.5 mm (10.059 in.)
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-145

AT7774
SST
AT7775
Fulcrum
Length
SST
AT7776
SST
AT7773
3. INSTALL SPACER
Install a new spacer to the driven pinion.
4. INSTALL DRIVEN PINION REAR SIDE BEARING
(a) Install the bearing cage to the driven pinion.
(b) Using a press and SST, install the rear side bearing
to the driven pinion.
SST 09506-35010
5. ADJUST DRIVEN PINION PRELOAD
(a) Using SST, torque a new nut.
SST 09326-2001 1
Torque: 1,000 kg-cm (72 ft-lb, 98 N-m)
HINT: Use a torque wrench with a fulcrum length of
42.5 cm (16.732 in.).
(b) Using a spring tension gauge and SST, measure
the preload.
SST 09326-2001 1
HINT: Turn the driven pinion right and left two or three
times to allow the bearings to settle.
Preload (at starting):
New bearing
1.8 - 2.9 kg (4.0 - 6.4 lb, 18 - 28 N)
Reused bearing
0.9 - 1.4 kg (2.0 - 3.1 lb, 9 - 14 N)

If preload is greater than specification, replace
the bearing spacer.

If preload is less than specification, retighten
the nut 5° - 10°at a time until the specified
preload is rechecked.
If the maximum torque is exceeded while retightening
the nut, replace the bearing spacer and repeat the pre-
load procedure.
Do not back off the pinion nut to reduce the preload.
Maximum torque: 2,400 kg-cm (174 ft-lb, 235 N-m)
NOTICE: Using the soft jaws, hold the bearing cage in
a vise.
- TRANSFER (A540H)Component Parts (Driven Pinion Bearing Cage)TF-9

SpringFree length
mm (in.)Coil outer diameter
mm (in.)Total No. of Coils
Color
Transfer clutch modulator valve 32.3 (1.272) 7.6 (0.299) 16None
No. 2 Low-high shift valve
28.9 (1.138) 7.0 (0.276) 14None
No. 1 Low-high shift valve
RetainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
6.5
(0.256)5.0
(0.197)3.2
(0.126) No. 2 Low-high shift valve
No. 1 Low-high shift valve
AT4425
PlugRetainerNo. 1 Low-High
Shift ValveLower Valve Body Transfer Clutch
Modulator ValveNo. 2 Low-High
Shift Valve
Transfer Lower Valve Body
COMPONENTS
SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS AND RETAINERS
HINT: During reassembly please refer to the spring specifications above to help discriminate between the
different springs.
TF-28- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)

AT4612
AT4964
Shift Fork ShaftShift Fork
AT4610
AT4614 AT4613
GasketPlate
ASSEMBLY OF TRANSFER VALVE BODY
1. INSTALL PLATE AND NEW GASKETS ON TRANSFER
LOWER VALVE BODY
Install a new gasket and plate and then the other new
gasket.
HINT: Both gaskets are the same.
2. INSTALL TRANSFER LOWER VALVE BODY
Each bolt length (mm, in.) is indicated in the figure.
(a) Lower the transfer lower valve body into place.
(b) Hand tighten the eight bolts first. Then, tighten
them with a torque wrench.
Torque: 67 kg-cm (58 in.-lb, 6.6 N-m)
ASSEMBLY OF TRANSFER LEFT CASE
1. INSTALL SHIFT FORK SHAFT TO SHIFT FORK
(a) Insert the shift fork shaft into the shift fork.
(b) Install the ball, spring and head plug.
(c) Tighten the plug.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
2. INSTALL SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
3. INSTALL TRANSFER SHIFT LEVER
(a) Coat the lip of new oil seal with MP grease.
(b) Using a 17 mm (0.67 in.) socket wrench and
hammer, drive in the oil seal as shown.
- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)TF-29

AT4419
SST
AT4493
SST
AT4494
AT4495AT4524
4. ADJUST TOTAL PRELOAD
(a) Install the transfer right case.
(b) Install and torque the ten bolts.
Torque: 450 kg-cm (33 ft-lb, 44 N-m)
HINT: Do not apply seal packing and do not install gasket.
Each bolt length (mm, in.) is indicated in the figure.
(c) Using SST and a spring tension gauge, measure
the total preload.
SST 09326-2001 1
Preload (at starting):
Add driven pinion preload
0.5 - 0.9 kg (1.1 - 2.0 lb, 4.9 - 8.8 N)
HINT: Turn the drive pinion counterclockwise and clock-
wise several times.
(d) Adjust the total preload by tightening the adjusting
nut with SST.
SST 09318-12010
HINT: Measure the preload while tightening the bearing
adjusting nut a little at a time.
5. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear back-
lash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
(b) When the backlash is outside the standard value,
select a different plate washer to the one selected in
step 3. Again adjust the backlash and total preload.
6. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at four different positions on the
ring gear with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
- TRANSFER (A540H)Assembly of Component PartsTF-33

AT4508
Lock Plate
AT4525
AT4308
AT4418
O-Ring Gasket
AT4524
(i) Install the right case to the left case.
(j) Install and torque the ten bolts.
Torque: 450 kg-cm (33 ft-lb, 44 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
16. CHECK TOTAL PRELOAD
(See page AT-126)
17. INSTALL ADJUSTING NUT LOCK PLATE
(a) Install the lock plate so that the projection from
the lock plate fits properly into the groove of the
adjusting nut.
HINT: When the lock plate cannot be installed, tighten
the adjusting nut the smallest amount possible.
(b) Coat a new O-ring with gear oil and install it to
the lock bolt.
(c) Install and torque the lock bolt.
Torque: 73 kg-cm (63 in.-lb, 7 N-m)
18. INSTALL TRANSFER INSPECTION HOLE COVER
(a) Apply seal packing to the left case as shown in the
figure.
Seal packing: Part No. 08826-00090 THREE BOND
1281 or equivalent
HINT: Install the cover as soon as the seal packing is
applied.
(b) Install the hole cover to the transfer left case.
(c) Install and torque the three bolts.
Torque: 160 kg-cm (12 ft-lb. 16 N-m)
19. INSTALL TRANSFER RIGHT CASE RETAINER
(a) Coat a new O-ring with gear oil, and install it and
new apply gasket.
- TRANSFER (A540H)Assembly of Component PartsTF-37