1986 TOYOTA CAMRY V20 differential

AT3691
A540E
AT3692
AT3595
SST
AT3594
A540E
AT3605
INSTALLATION OF DIFFERENTIAL AND
DRIVE PINION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
(a) Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with the
pinion shaft. (A540E)
(b) Install the two new O-rings to the bearing cage.
(A540E)
(c) Coat the O-rings with ATF. (A540E)
(d) Using a hammer and brass bar, slightly tap the
bearing cage into the transaxle case until the
snap ring groove in the bore can be seen.
(e) Using SST, install snap ring into the bore.
SST 09350-32014 (09351-32050)
2. (A540E)
PLACE SENSOR ROTOR ONTO DRIVE PINION SHAFT
AT-122- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT3989
AT3697
Shim Outer Race A540E
AT3585
A540E
AT3588
(c) Turn the gear counterclockwise and clockwise sev-
eral times.
(d) Using a torque meter, measure the preload of the
drive pinion.
Drive pinion preload (at starting):
New bearing
10 - 16 kg-cm
(8.7 - 13.9 in.-lb, 1.0 - 1.6 N-m)
Reused bearing
5 - 8 kg-cm
(4.3 - 6.9 in.-lb, 0.5 - 0.8 N-m)
If the preload is greater than specified,
replace the bearing spacer.
If the preload is less than specified, retigh-
ten the nut 130 kg-cm (9 ft-lb, 13 N-m) at
a time until the specified preload is
reached.
If the maximum torque is exceeded while retightening the
nut, replace the bearing spacer and repeat the preload
procedure.
Do not back off the nut to reduce the preload.
Maximum torque: 3,600 kg-cm (260 ft-lb, 353 N-m)
(e) If the preload is adjusted within specification, make
a note of it.
(f) Stake the lock nut.
8. (A540E)
PLACE OUTER RACE AND SHIM ONTO RH SIDE
BEARING
9. PLACE DIFFERENTIAL CASE INTO TRANSAXLE
CASE
(A540E)
Be sure to install the shim and outer race into place.
AT-124- AUTOMATIC TRANSAXLEInstallation of Component Parts

New BearingReused Bearing
A540E2.8 - 4.4
(2.4 - 3.8, 0.3 - 0.4)1.4 - 2.2
(1.2 - 1.9, 0.1 - 0.2)
A540H2.3 - 3.7
(2.0 - 3.2, 0.2 - 0.4)1.2 - 1.9
(1.0 - 1.6, 0.1 - 0.2)
AT4170
AT4171
AT3700
Adjusting Shim
MarkThicknessMarkThickness
0
1
2
3
4
5
6
7
82.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)
2.35 (0.0925)
2.40 (0.0945)9
A
B
C
D
E
F
G
H2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)
2.70 (0.1063)
2.75 (0.1083)
2.80 (0.1102)
2.85 (0.1122)
A540H
AT4173
mm (in.)
11. ADJUST SIDE SEARING PRELOAD
(a) Remove any packing material on the contacting
surfaces of the LH bearing retainer and transaxle
case.
HINT: Do not apply seal packing yet.
(b) Install the LH bearing retainer and torque the six
bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(c) Snap down the bearings by turning the differential
case several times.
(d) Using a torque meter, measure the differential total
preload.
Total preload (at starting)
Add drive pinion preload
kg-cm (in.-lb, N-m)
If the preload is not within specification, replace the
adjusting shim in the LH bearing retainer with another
thickness one.
AT-126- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT4563
AT3711
AT3712
SST
AT4170
12. INSTALL LH BEARING RETAINER
(a) Remove the six bolts and LH bearing retainer.
(b) Remove any packing material on the contacting
surfaces of LH bearing retainer, transaxle case
and carrier cover.
(c) Apply the seal packing to the transaxle case and
carrier cover as shown.
Seal packing: Part No. 08826 - 00090, THREE
BOND 1281 or equivalent
HINT: Install the LH bearing retainer with ten minutes
after applying seal packing.
(d) Install the LH bearing retainer.
(e) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND
1324 or equivalent
(f) Tighten the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
(g) Snap down the bearings.
(h) Recheck the differential total preload.
AT4170
13. INSTALL NEW OIL SEAL
(a) Place the oil baffle onto the LH bearing retainer.
(b) Using SST, driven in a new oil seal until its end is
flush with the surface of the LH bearing retainer.
SST 09223-15010
- AUTOMATIC TRANSAXLEInstallation of Component PartsAT-127

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

AT4576
A540H
AT4600
A540H
AT4309
A540H
AT4221
A540H50. (A540H)
INSTALL APPLY GASKET
Install a new apply gasket to the differential carrier cover.
51. (A540H)
INSTALL TRANSFER ASSEMBLY
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of the transfer
and transaxle.
(b) Apply seal packing to the transaxle as shown in the
illustration.
Seal packing: Part No. 08826 - 00090, THREE BOND
1281, or equivalent
HINT: Install the transfer assembly as soon as the seal
packing is applied.
(c) Coat the threads of bolts with sealer.
Sealer: Part No. 08833 - 00070, THREE BOND 1324
or equivalent.
(d) Install and torque the five nuts and three bolts.
Torque: 700 kg-cm (51 ft-lb, 69 N-m)
52. (A540H)
INSPECT MODE SELECT LEVER POSITION
After finishing inspection or repair the transaxte, be sure
the select lever position to FREE mode and attach the
lock bolt.
AT-146- AUTOMATIC TRANSAXLEInstallation of Component Parts

AT4423
AT4424
Gasket
AT4507
Strainer Drive Gear
AT4421
ShimO-ring
9. REMOVE DRIVEN PINION BEARING CAGE
(a) Remove the six bolts and bearing cage.
(b) Remove the O-ring and the shims from the bearing
cage.
10. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and right case.
AT4422
11. REMOVE CENTER DIFFERENTIAL ASSEMBLY
12. REMOVE APPLY GASKET
Remove the apply gasket from the left case.
13. REMOVE OIL PUMP DRIVEN GEAR AND OIL PUMP
STRAINER
(a) Remove oil pump driven gear.
(b) Remove the bolt and oil pump strainer.
(c) Remove the O-ring from the oil pump strainer.
- TRANSFER (A540H)Disassembly of Component PartsTF-5

AT4509
Adjusting NutSST
Oil Reserver
AT7764
AT4510
AT4511 AT4508
Bolt Lock Plate
14. REMOVE ADJUSTING NUT LOCK PLATE
(a) Remove the bolt and nut lock plate from the right
case.
(b) Remove the O-ring from the bolt.
15. REMOVE DIFFERENTIAL RIGHT SIDE BEARING
OUTER RACE
(a) Using SST, remove the adjusting nut and oil re-
server from the right case.
SST 09318-12010
(b) Using a brass bar, remove the outer race.
16. REMOVE DIFFERENTIAL LEFT SIDE BEARING
OUTER RACE
Using SST, remove the outer race and plate washer.
SST 09308-00010
17. REMOVE LEFT CASE OIL SEAL
Using SST, remove the oil seal.
SST 09308-00010
TF-6- TRANSFER (A540H)Disassembly of Component Parts