1986 TOYOTA CAMRY V20 brake

AT0198 AT0376
SST
AT0199
AT3572
AT2729 AT0197
(c) Push the piston into the bore of the case, facing
the spring seat upward.
6. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring on the piston.
(b) Place SST, and compress the return spring evenly
by tightening the bolt gradually.
SST 09350-32014 (09351-32040)
(c) Install snap ring. Visually check to make sure it is
fully seated and centered by the three lugs on the
spring retainer.
Be sure the end gap of snap ring is not aligned with
the spring retainer claw.
(d) Remove SST.
7. INSTALL SNAP RING TO TRANSAXLE CASE
8. INSTALL OVERDRIVE UNIT
(a) Install the overdrive brake apply gasket and over-
drive clutch apply gasket.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-131

AT7731
AT3714
AT4169
AT7760 AT2728
(b) Install the overdrive brake drum to the case.
(c) Install the new case gasket to the case.
(d) Make sure that the length from the top surface of
the case to the counter driven gear top surface
should be about 24 mm (0.94 in.)
(e) Place the new gasket onto the transaxle case.
(f) Install the overdrive assembly with overdrive case
to the transaxle case.
(g) Coat the threads of 23 mm (0.91 in.) bolts with
sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324
or equivalent.
(h) Install and tighten the thirteen bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)
HINT: Each bolt length (mm, in.) is indicated in the figure.
9. CHECK INTERMEDIATE SHAFT END PLAY
(a) Make sure that the intermediate shaft has thrust
play in axial direction.
Thrust play: 0.47 - 1.50 mm (0.0185 - 0.0591 in.)
If the thrust play is not within specification, check the
installation of intermediate shaft.
(See page AT-83)
(b) Make sure that the intermediate shaft turns
smoothly.
AT-132- AUTOMATIC TRANSAXLEInstallation of Component Parts

Outer Diameter
Inner Diameter
A540E
Bearing38.7 (1.524)
22.6 (0.890)
A540HFront Race37.3 (1.469)
24.1 (0.949)
Bearing37.6 (1.480)
24.0 (0.945)
Rear Race37.6 (1.480)
22.2 (0.874)
AT3717
AT3716
AT3718
Plate
DiscFlange
AT3719AT5037
A540H A540E
Bearing and race:mm (in.)
10. INSTALL REAR PLANETARY GEAR
(a) Install the rear planetary ring gear.
(b) (A540E)
Place the bearing onto the ring gear.
(c) (A540H)
Coat the races and bearing with petroleum jelly
and install them onto the ring gear.
(d) Coat the thrust washer with petroleum jelly and
place it onto the rear planetary gear.
(e) Install the rear planetary gear.
11. INSTALL DISCS, PLATES AND FLANGE OF FIRST
AND REVERSE BRAKE
(a) Install the seven plates and seven discs.
Install in order: P = Plate D = Disc
A540E: P-D-P-D-P-D-P-D-P-D-P-D-P-D
A540H: P-D-P-D-P-D-P-D-P-D-P-D
(b) Install the flange, facing the flat end downward.
(c) Install the snap ring.
HINT: Be sure that the end gap of the snap ring is not
aligned with one of cutouts.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-133

AT3602
AT3720
AT3721
SST
AT5022
Thrust
Washer
AT3563
12. CHECK FIRST AND REVERSE BRAKE
(a) Check the operation of the first and reverse brake
piston.
Apply compressed air into the case passage and confirm
that the piston moves.
(b) Using a filler gauge, check the pack clearance of
the first and reverse brake.
Clearance: A540E
0.85 - 2.05 mm (0.033 - 0.081 in.)
A540H
1.04 - 2.16 mm (0.041 - 0.085 in.)
13. INSTALL NO. 2 ONE-WAY CLUTCH INTO CASE
(a) Place the No. 2 one-way clutch with the shiny
side of flange upward.
(b) Install the one-way clutch while turning the plane-
tary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If can not turn the planetary gear clockwise, check the
installation of the one-way clutch.
(c) Install the snap ring.
HINT: Be sure that the end gap of the snap ring is not
aligned with one of cutouts.
(d) (A540H only)
Coat the thrust washer with petroleum jelly and
install it onto the rear planetary gear.
AT-134- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3724
A540E
AT3725
AT3726
FlangePlate Disc
AT3556 AT3723
14. INSTALL SECOND COAST BRAKE BAND GUIDE
15. PLACE NO. 1 ONE-WAY CLUTCH
(a) Coat the thrust washer with petroleum jelly and
install it on the No. 1 one-way clutch. (A540E)
(b) Place the No. 1 one-way clutch onto the rear
planetary gear.
16. INSTALL SECOND BRAKE
(a) Install the flange, facing the flat end upward.
(b) Install the three discs and plates.
Install in order: P = Plate D = Disc
D-P-D-P-D-P
(c) Place the piston return spring into the case.
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-135

AT0335
AT7761
AT3601
AT3727 AT0334
(d) Place the second brake drum into the case.
HINT: Align the groove of the drum with the bolt.
(e) Place the snap ring into the case so that end gap
is installed into the groove.
(f) While compressing the piston return springs over
the drum with hammer handles, install the snap
ring into the groove.
(g) Be sure that the end gap of the snap ring is not
aligned with one of cutouts.
17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the
second brake drum.
18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket and
confirm that the piston moves.
19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
(a) Coat the thrust washer with petroleum jelly and
install it on the sun gear input drum.
AT-136- AUTOMATIC TRANSAXLEInstallation of Component Parts

ThicknessOuter Diameter Inner Diameter
Bearing3.60 (0.1417) 45.9 (1.807)27.7 (1.091)
4.19 (0.1650) 47.1 (1.854)27.7 (1.091)
ThicknessOuter DiameterInner Diameter
Front Race0.8 (0.0315)
43.0 (1.693)30.5 (1.201)
1.4 (0.0551)
Bearing42.0 (1.654)28.9 (1.138)
Rear Race42.0 (1.654)27.1 (1.067) Outer Diameter
Inner Diameter
A540E Bearing47.6 (1.874)
31.4 (1.236)
A540HBearing36.1 (1.421) 22.2 (0.874)
Race37.9 (1.492)
22.0 (0.866)
AT5034
A540E A540H
AT5035
A540H A540E
AT3733
Thrust Washer
AT3734 AT0346
Bearing: A540Emm (in.)
Bearing and racemm (in.)
23. INSTALL SECOND COAST BRAKE BAND
(a) Place the band into the case.
(b) Install the pin through the oil pump mounting bolt
hole.
24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
(a) Coat the race and bearing with petroleum jelly and
install it onto rear side of the forward clutch.
(b) Coat the race and bearing with petroleum jelly and
install it onto front side of the forward clutch.
HINT: There are two different-thick races (A540H) and
bearings (A540E) for adjustment of the input shaft thrust
play.
Bearing and race: A540H
mm (in.)
(c) Coat the thrust washer with petroleum jelly and
install it with the oil groove facing upward onto the
direct clutch drum.
(d) Mesh the hub of the forward clutch with flukes of
the direct clutch discs.
HINT: Be careful that the bearing and thrust washer do
not get out of place.
AT-138- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3543
SST
AT3541
AT3542 AT3544
CoverO-Rings Piston Spring
27. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
28. INSTALL SECOND COAST BRAKE PISTON
(a) Coat the new O-rings with ATF and install it to the
cover.
(b) Install the outer spring with the piston.
(c) Place the cover into the bore.
(d) Using SST, install the snap ring while pressing the
cover.
SST 09350-32014 (09351-32050)
(e) Check that the front end of the piston rod contacts
the center of the second brake band depression.
29. CHECK SECOND COAST BRAKE PISTON STROKE
(a) Apply a small amount of paint to the piston rod at
the point it meets the case shown in the illustration.
(b) Using SST, measure the piston stroke applying
and releasing the compressed air (4 - 8 kg/cm
2,
57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 in.)
If the stroke is more than specified, replace the piston
rod with a longer one.
Piston rod length: 95.2 mm (3.748 in.)
96.3 mm (3.791 in.)
It is still more than standard value, replace the brake
band with a new one.
AT-140- AUTOMATIC TRANSAXLEInstallation of Component Parts