1986 TOYOTA CAMRY V20 torque

AT4604
Matchmarks
AT4674
Stopper
AT4514AT4515
Relief Valve3. REMOVE RELIEF VALVE
Remove the relief valve and spring.
ASSEMBLY OF TRANSFER RIGHT CASE
1. INSTALL RELIEF VALVE
Install the relief valve and spring.
2. INSTALL OIL PUMP DRIVE ROTOR AND DRIVEN
ROTOR
Align the matchmarks on the drive rotor and the driven
rotor.
3. INSTALL OIL PUMP COVER AND DRIVEN GEAR
STOPPER
Torque the three bolts evenly.
Torque: 80 kg-cm (69 in.-lb, 7.8 N-m)
4. CHECK OPERATION OF OIL PUMP
Insert the oil pump driven gear to the drive rotor, check
that the drive rotor turns smoothly.
- TRANSFER (A540H)Component Parts (Transfer Right Case)TF-15

AT4516
r Non-reusable part-cm (ft-lb, N-m)
: Specified torqueSide Gear Thrust WasherDifferential Side Left GearDifferential Pinion Shaft Holder Differential Pinion Thrust Washer Center Differential CaseSpacerRight GearWasherConical Spring 985 (71, 97)Oil Pump Drive GearShaft Snap
Ring r Left Case
BearingTransfer
Ring GearRing Gear Mounting
Left Caser O-RingRing Gear Mounting
Right Caser Right Case Bearing
Differential Pinion Thrust Washer
Differential Pinion Shaft Shaft Snap
RingDifferential Side
Ring Gear Mounting Case and
Center Differential Case
COMPONENTS
DISASSEMBLY OF RING GEAR MOUNTING
CASE AND CENTER DIFFERENTIAL CASE
1. REMOVE OIL PUMP DRIVE GEAR
(a) Using a screwdriver, remove the shaft snap ring.
TF-16- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)

AT7783Matchmarks
AT7796
Conical Spring
Washer Thickness
AT7797
Mark Thickness mm (in.)Mark Thickness mm (in.)
A
B
C
D
E
F1.00 (0.0394)
1.05 (0.0413)
1.10 (0.0433)
1.15 (0.0453)
1.20 (0.0472)
1.25 (0.0492)G
H
J
K
L1.30 (0.0512)
1.35 (0.0531)
1.40 (0.0551)
1.45 (0.0571)
1.50 (0.0591)
AT7786
1.05
(0.0413) 1.00
(0.0394) 0.95
(0.0374)
Conical spring washer thickness
mm
(in.)
(h) Referring to the table below, select the thrust washer
which will ensure that the backlash is within specifi-
cation. Try to select a washer of the same size.
Standard clearance
(c) Install the thrust washer.
(d) Align the matchmarks on the ring gear mounting
left and right case.
(e) Install and torque the twelve bolts.
Torque: 985 kg-cm (71 ft-lb, 97 N-m)
HINT: Do not install the O-ring.
(f) Using a caliper, measure the conical spring washer
thickness.
(g) Using a dial indicator, measure the thrust clearance
of center differential case while holding the ring
gear mounting case.
Standard clearance:
Thrust clearance
mm
(in.)
0.60
(0.0236)
0.50
(0.0197)
0.40
(0.0157)
0.30
(0.0118)
0.20
(0.0079)
0.10
(0.0039)
AT3460
(i) Remove ring gear mounting right case.
TF-22- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)

AT7787
AT7786
AT7783
Matchmarks
AT7799 AT7798
6. INSTALL DIFFERENTIAL SIDE GEAR AND CONICAL
SPRING WASHER
HINT: Be careful not to make a mistake in the direction
of the conical spring washer.
7. INSTALL CENTER DIFFERENTIAL CASE
8. INSTALL THRUST WASHER (Previously selected)
9. INSTALL RING GEAR MOUNTING LEFT CASE
(a) Coat the new O-ring with ATF, and install it onto
the left case.
(b) Align the matchmarks on the right and left case.
(c) Install and torque the twelve bolts.
Torque: 985 kg-cm (71 ft-lb, 97 N-m)
NOTICE: Using the soft jaws, hold the left case in a vise.
10. INSTALL OIL PUMP DRIVE GEAR
(a) Install the oil pump drive gear.
- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)TF-23

AT4605
r Non-reusable part

Precoated part: Specified torque
kg-cm (ft-lb, N-m)Differential Lock
Shift Fork ShaftTransfer Left Case Differential Lock
Shift Forkr Oil Seal Ball Spring
120 (9, 12)
Head PlugTransfer Shift Lever Valve Body StrainerDifferential Lock Sleeve Transfer Valve Body
Gasket r Transfer Case GasketTransfer Valve Body Assemblyr O-ring
110 (8, 11)Center Differential Control Solenoidr O-ring
70 (61 in.-lb, 6.9) 145 (10, 14)
Transfer Left Case
COMPONENTS
- TRANSFER (A540H)Component Parts (Transfer Left Case)TF-25

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

AT4607
Strainer
Gasket
AT4606
AT4520
O-ringO-ring
AT4519 AT4615
Lock BoltShift
Lever Shift
Fork
(c) Install transfer shift lever.
HINT: Engage shift fork and transfer shift lever.
(d) Install and tighten the lock bolts.
Torque: 40 kg-cm (35 in.-lb, 3.9 N-m)
4. INSTALL TRANSFER VALVE BODY ASSEMBLY
(a) Install the new transfer case gaskets and valve
body strainer.
(b) Install the new transfer valve body gasket.
(c) Install the transfer valve body assembly.
(d) Tighten the bolts.
Torque: 110 kg-cm (8 ft-lb, 11 N-m)
5. INSTALL CENTER DIFFERENTIAL CONTROL
SOLENOIDS
(a) Install the four new O-rings to the solenoids.
(b) Coat the O-rings with ATF.
(c) Install the solenoids.
Torque: 145 kg-cm (10 ft-lb, 14 N-m)
TF-30- TRANSFER (A540H)Component Parts (Transfer Lower Valve Body)

AT4491
AT4492
Mark Thickness
Mark Thickness
712.13 (0.0839)
832.49 (0.0980)
72 2.16 (0.0850)
842.52 (0.0992)
732.19 (0.0862)
852.55 (0.1004)
742.22 (0.0874)
862.58 (0.1016)
752.25 (0.0886)
872.61 (0.1028)
762.28 (0.0898)
882.64 (0.1039)
772.31 (0.0909)
892.67 (0.1051)
782.34 (0.0921)
902.70 (0.1063)
792.37 (0.0933)
912.73 (0.1075)
802.40 (0.0945)
922.76 (0.1087)
812.43 (0.0957)
932.79 (0.1098)
822.46 (0.0969)
942.82 (0.1110)
AT3364
AT4521
Plate washer thicknessmm (in.)
(b) Install the driven pinion bearing cage.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
HINT: Do not install the O-ring.
(c) Install the ring gear mounting case and center
differential case.
(d) Using a dial indicator, measure the ring gear back-
lash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
(e) Referring to the table below, select the plate washer
which will ensure that the backlash is within specifi-
cation. Try to select a washer of the same size.
TF-32- TRANSFER (A540H)Assembly of Component Parts