1986 TOYOTA CAMRY V20 differential

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

AT7800
(b) Install the shaft snap ring.
TF-24- TRANSFER (A540H)Component Parts (Ring Gear Mounting
Case and Center Differential Case)

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

AT4520
O-ringO-ring
AT4606
AT4607
GasketStrainer
AT4608
Shift Lever
AT4519
DISASSEMBLY OF TRANSFER LEFT CASE
1. REMOVE CENTER DIFFERENTIAL CONTROL
SOLENOIDS
(a) Remove the four bolts and solenoid.
(b) Remove the four O-rings from the solenoids.
2. REMOVE TRANSFER VALVE BODY ASSEMBLY
(a) Remove the eight bolts and transfer valve body
assembly.
(b) Remove the transfer valve body gasket.
(c) Remove transfer case gaskets and valve body
strainer.
3. REMOVE TRANSFER SHIFT LEVER
(a) Remove the lock bolt and transfer shift lever.
TF-26- TRANSFER (A540H)Component Parts (Transfer Left Case)

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

Mark ThicknessMark Thickness
A
B
C
D
E0.30 (0.0118)
0.33 (0.0130)
0.36 (0.0142)
0.39 (0.0154)
0.42 (0.0165)F
G
H
J
K0.45 (0.0177)
0.48 (0.0189)
0.51 (0.0201)
0.54 (0.0213)
0.57 (0.0224)
AT4310
Shim
AT4524
AT4492AT3397
Select an adjusting shim that will shift the
driven pinion away from the ring gear.Flank Contact Toe ContactSelect an adjusting shim that will bring the
driven pinion closer to the ring gear. Proper ContactFace Contact Heel Contact
Shim thicknessmm (in.)
(c) If the teeth are not connecting properly, again the
proper shim and plate washer.
7. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and transfer right case.
8. REMOVE RING GEAR MOUNTING CASE AND CENTER
DIFFERENTIAL CASE
TF-34- TRANSFER (A540H)Assembly of Component Parts

AT4510
AT4616
AT4521
AT4522
SST
AT4491
9. REMOVE DRIVEN PINION BEARING CAGE
ASSEMBLY
Remove the six bolts and driven pinion bearing cage
assembly.
10. REMOVE DIFFERENTIAL LEFT SIDE BEARING
OUTER RACE AND PLATE WASHER
Using SST, remove the outer race and plate washer.
SST 09308-00010
11. INSTALL OIL SEAL
(a) Using SST, install a new oil seal as shown.
SST 09316-60010 (09316-00010, 09316-00030)
Oil seal depth: 3 mm (0.12 in.)
(b) Coat the lip of oil seal with MP grease.
12. INSTALL LEFT CASE BEARING OUTER RACE
(a) Install the plate washer. (previously selected)
(b) Using SST and a press, press in the outer race.
SST 09316-60010 (09316-00010, 09316-00060)
- TRANSFER (A540H)Assembly of Component PartsTF-35