1986 TOYOTA CAMRY V20 length

HINT: During reassembly please refer to the spring specifications above to help discriminate be-
tween the different springs.
SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS
AND RETAINERS
(Transfer Lower Valve Body)
COMPONENTS
Transfer clutch modulator valveTransfer clutch modulator valveCoil outer diameter
mm (in.)
No. 2 Low±high shift valveNo. 2 Low±high shift valve
No. 1 Low±high shift valveNo. 1 Low±high shift valveFree length
mm (in.)Total No. of Coils
Thickness
mm (in.) Height mm
(in.)Width
mm (in.) RetainerSpring
Color
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±369

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 tower valve body into place.
(b1 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±Ib, 25 N±m)
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 ham
mer, drive in the oil seal as shown. 2. INSTALL SHIFT FORK SHAFT, SHIFT FORK AND
SLEEVE
± AUTOMATIC TRANSAXLEComponent Parts(Transfer Transfer Lower Valve Body
A540H)AT±370

4. ADJUST TOTAL PRELOAD
(a) Install the transfer right case.
(b) Install and torque the ten bolts.
Torque: 450 kg±cm (33 ft±Ib, 44 N±m)
HINT: Do not apply seal packing and do not install gas-
ket. Each bolt length (mm (in.) is indicated in the figure.
(c) Using SST and a spring tension gauge, mea-
sure the total preload.
SST 09326±20011
Preload (at starting):
Add driven pinion preload
0.5±0.9kg (1.1 ±2.0lb,4.9±8.8N)
HINT: Turn the drive pinion counterclockwise and
clockwise several times.
5. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear backlash.
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. (d) Adjust the total preload by tightening the adjust-
ing nut with SST.
SST 09318±12010
HINT: Measure the preload while tightening the
bearing adjusting nut a little at a time.
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.
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±374

(c) Install and torque the lock bolt.
Torque: 73 kg±cm (63 in.±Ib, 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±Ib, 16 N±m)
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 adjust-
ing 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. Install the right case to the left case.
Q) Install and torque the ten bolts.
Torque: 450 kg±cm (33 ft±b. 44 N±m)
HINT: Each bolt length (mm (in.)) is indicated in the figure.
16. CHECK TOTAL PRELOAD
(See page AT±388)
19. INSTALL TRANSFER RIGHT CASE RETAINER
(a) Coat a new O±ring with gear oil, and install it and new
apply gasket.
± AUTOMATIC TRANSAXLEComponent Parts (Transfer Transfer Lower Valve Body
A540H)AT±378

10. INSTALL CARRIER COVER
(a) Remove any packing material and be careful not to drop oil on
the contacting surfaces of the carrier cover and transaxle
case.
(b) Apply seat packing to the carrier cover as shown.
Seal packing: Part No. 08826±00090, THREE BOND
1281 or equivalent
HINT: Install the carrier cover within ten minutes after applying
seal packing.
(d) Install and torque the eleven bolts.
Torque: 400 kg±cm (29 ft±lb, 39 N±m)
HINT: Each bolt length (mm (in)) is indicated in the
figure. (A540H)
Be sure to install the ring gear mount case sleeve
and outer race into place.
(e) Install the two apply gaskets.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±387

9. CHECK INTERMEDIATE SHAFT END PLAY
(a) Make sure that the intermediate shaft has thrust plate)
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 installa-
tion of intermediate shaft.
(See page AT±306)
(b) Make sure that the intermediate shaft turns smoothly.(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±Ib, 25 N±m)
HINT: Each bolt length (mm (in.)) is indicated in the figure. (e) Place the new gasket onto the transaxle case.
M Install the overdrive assembly with overdrive
case to the transaxle 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.) (b) Install the overdrive brake drum to the case.
(c) Install the new case gasket to the case.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±394

(b) Using SST, measure the piston stroke applying an(
releasing the compressed air (4 ± 8 kg/cm2, 57 ±
114 psi or 392 ± 785 kPa) as shown.
SST 09240±00020
Piston stroke: 2.0 ± 3.5 mm (o.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 ban(
with a new one. 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 con-
tacts the center of the second brake band de-
pression.
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.
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±402

33. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the
cable end into the slot.
(b) Lower the valve body into place.
NOTICE: Do not entangle the solenoid wire.
(c) Place the cover with a new gasket and gradually
tighten the bolts a little a time in sequence.
HINT: Each bolt length (mm (in.)) is indicated in
the figure.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
34. INSTALL ACCUMULATOR PISTONS AND SPRINGS
(a) Install the new O±rings to the pistons.
(b) Install the springs and pistons into the bores.
31. PLACE NEW SECOND BRAKE APPLY GASKET
32. INSTALL THROTTLE CABLE AND SOLENOID WIRE
Outer diameter
mm (in.) Free length
mm (in.) SpringColor
± AUTOMATIC TRANSAXLEInstallation of Component Parts (A540E and A540H)AT±403