Page 3 of 2389
Illustration:
what to do and where
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task head-
ing can be read at a glance and only when necessary, the text
below it provides detailed information. Important specifications
and warnings always stand out in bold type.SST 09350-32014 (09351-32190) If replacing the disc, plate or flange, check the piston
stroke:
Set part No.
Piston stroke: 1.41 - 1.82 mm (0.0555 - 0.0717 in.) The procedures are presented in a step-by-step format:
Illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and
gives other information such as specifications and
warnings.
Example:
Task heading: what to do
7. CHECK PISTON STROKE OF FORWARD CLUTCH
Detail text: how to do it
Using a dial indicator (long type pick or SST), measure
the forward clutch piston stroke applying and releasing
the compressed air (4 - 8 kg/cm
2, 57 - 114 psi or 392
- 785 kPa) as shown.
Component part No.
Specification
REFERENCES
References have been kept to a minimum. However, when
they are required you are given the
page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A, specifications for quick reference.
CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate
there is a possibility of injury to you or other people.
NOTICES are also presented in bold type, and indicate
the possibility of damage to the components being re-
paired.
HINTS are separated from the text but do not appear in
bold. They provide additional information to help you effi-
ciently perform the repair.
- INTRODUCTIONHow to Use This ManualIN-3
Page 6 of 2389
ABBREVIATIONS USED IN THIS MANUAL
A/T ATM Automatic Transmission
ATF Automatic Transmission Fluid
B
0 Overdrive Brake
B
1 Second Coast Brake
B
2 Second Brake
B
3 First and Reverse Brake
C
0 Overdrive Clutch
C
1 Forward Clutch
C
2 Direct Clutch
D Disc
D/F Differential
LH Left
MP Multipurpose
O/D Overdrive
P Plate
RH Right
SSM Special Service Materials
SST Special Service Tools
IN-6- INTRODUCTIONAbbreviations Used in This Manual
Page 13 of 2389
Second
coast brakePiston stroke
Piston rod length2.0 - 3.5 mm
95.2 mm
96.3 mm0.079 - 0.138 in.
3.748 in.
3.791 in.
Oil pump
STD
Maximum
STD
Maximum
STD
Maximum
Maximum
Maximum
Maximum Body clearance
Tip clearance
Side clearance
Pump body bushing inside diameter
Stator shaft bushing inside diameter
Front side
Rear side0.07 - 0.15 mm
0.3 mm
0.11 - 0.14 mm
0.3 mm
0.02 - 0.05 mm
0.1 mm
38.18 mm
21.57 mm
27.07 mm0.0028 - 0.0059 in.
0.012 in.
0.0043 - 0.0055 in.
0.012 in.
0.0008 - 0.0020 in.
0.004 in.
1.5031 in.
0.8492 in.
1.0657 in.
Direct clutch
Maximum Piston stroke
Drum bushing inside diameter
Flange thickness0.0358 - 0.0531 in.
1.9004 in.
0.1063 in.
0.1181 in. 0.91 - 1.35 mm
48.27 mm
2.70 mm
3.00 mm
Forward
clutchPiston stroke
Flange thickness1.41 - 1.82 mm
3.00 mm
3.37 mm0.0555 - 0.0717 in.
0.1181 in.
0.1327 in.
Front
planetary
gearMaximum
Maximum
STD
Maximum Sun gear bushing inside diameter
Ring gear flange bushing inside diameter
Planetary pinion gear thrust clearance22.59 mm
30.08 mm
0.16 - 0.56 mm
0.61 mm0.8894 in.
1.1842 in.
0.0063 - 0.0220 in.
0.024 in.
Rear
planetary
gearPlanetary pinion gear thrust clearance
STD
Maximum0.16 - 0.56 mm
0.61 mm0.0063 - 0.0220 in.
0.024 in.
First and
reverse brakePack clearance0.85 - 2.05 mm0.033 - 0.081 in.
Overdrive
unitDirect clutch piston stroke
Direct clutch bushing inside diameter
Counter drive gear preload
Planetary pinion gear thrust clearanceMaximum
at Starting
STD
Maximum0.0689 - 0.0980 in.
0.8713 in.
940 - 1,560 g 2.1 - 3.4 lb 9.2 - 15.3 N1.75 - 2.49 mm
22.13 mm
0.0063 - 0.0220 in.
0.024 in. 0.16 - 0.56 mm
0.61 mm
AUTOMATIC TRANSAXLE (A540E)
Specifications
A-2- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)
Page 16 of 2389
Second
coast brakeSame the A540E automatic transaxle (See page A-2)
Oil pump=
Direct clutch Piston stroke
Drum bushing inside diameter Maximum
Flange thickness1.11 - 1.47 mm
48.27 mm
2.70 mm
3.00 mm0.0437 - 0.0579 in.
1.9004 in.
0.1063 in.
0.1181 in.
Forward
clutchSame the A540E automatic transaxle (See page A-2)
Front
planetary gear=
Rear
planetary gear=
First and
reverse brakePack clearance 0.0409 - 0.0850 in.1.04 - 2.16 mm
Over drive
unitSame the A540E automatic transaxle (See page A-2)
Valve body
springSame the A540E automatic transaxle (See page A-3)
Valve body
retainerSame the A540E automatic transaxle (See page A-3)
Accumulator
springSame the A540E automatic transaxle (See page A-4) Part tightenedkg-cmft-lbN-m
Oil cooler pipe union
Oil pan
Valve body y Transaxle case
Accumulator y Cover
Oil pump y Transaxle case
O/D case y Transaxle case
Differential LH side bearing retainer
Differential RH retainer
Differential carrier cover
Oil pump body y Stator shaft
Upper valve body y Lower valve body
Differential left case y Right case
Ring gear y Differential case275
50
11 0
100
225
250
195
195
400
100
67
640
1,26027
4.9
11
10
22
25
19
19
39
10
6.6
63
124 20
43 in.-lb
8
7
16
18
14
14
29
7
58 in.-lb
46
91
Torque Specifications
AUTOMATIC TRANSAXLE (A540H)
Specifications
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-5
Page 18 of 2389
Transfer
(Cont'd)Center differential left side gear
thrust washer thickness
Center differential side gear
thrust clearance
Center differential right side gear
thrust washer thickness 0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0071 - 0.0248 in.
0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
0.0531 in.
0.0551 in.
0.0571 in.
0.0591 in. 1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
0.18 - 0.63 mm
1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
1.35 mm
1.40 mm
1.45 mm
1.50 mm
Transfer lower valve body springFree length
mm (in.)Coil outer
diameter
mm (in.)Total
No. of
coilsColor
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve32.2 (1.272)
28.9 (1.138)
28.9 (1.138)7.6 (0.299)
7.0 (0.276)
7.0 (0.276)16
14
14None
None
None
Transfer lower valve body retainerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve6.5 (0.256)
=
=5.0 (0.197)
=
=3.2 (0.126)
=
=
Center differential plate washer
2.13 mm
2.16 mm
2.19 mm
2.22 mm
2.25 mm
2.28 mm
2.31 mm
2.34 mm
2.37 mm
2.40 mm0.0839 in.
0.0850 in.
0.0862 in.
0.0874 in.
0.0886 in.
0.0898 in.
0.0909 in.
0.0921 in.
0.0933 in.
0.0945 in.
Specifications (Cont'd)
Mark
A
B
C
D
E
F
G
H
J
Mark
A
B
C
D
E
F
G
H
J
K
L
Mark
71
72
73
74
75
76
77
78
79
80
- SERVICE SPECIFICATIONSAutomatic Transaxle Transfer (A540E A540H)A-7
Page 21 of 2389
AT3754
Electronic Control
SystemDifferential Hydraulic Control
SystemTorque
ConverterLock-up
Clutch 4-speed Planetary
Gear Unit
Sectional View
DESCRIPTION
GENERAL
(A540E)
The A540E is a 4-speed, Electronic Controlled Transaxle (hereafter called ECT) developed exclusively
for use with a transversely-mounted engine. A lock-up is built into the torque converter.
The A540E transaxle is mainly composed of the torque converter, the 4-speed planetary gear unit, the
differential, the hydraulic control system and the electronic control system.
AT-2- AUTOMATIC TRANSAXLEDescription
Page 22 of 2389
AT5032
(A540H)
The A540H automatic transaxle design is based on the A540E automatic transaxle and equipped with a
center differential and transfer.
This transaxle has the same hydraulic multiplate clutch in the center differential limiting control mecha-
nism as the A241H automatic transaxle on the Corolla All-Trac/4WD Station Wagon. The fluid pressure
acting on the hydraulic multiplate clutch of the A540H is controlled by the ECT ECU (Electronic Control
Unit) according to the vehicle driving conditions. As a result, torque is distributed to the front and rear
wheels appropriately at all times to maximize the overall performance of the 4WD vehicle.
NOTICE: Special handling methods are necessary for full-time 4WD vehicles during inspection and
maintenance. Instructions concerning these handling methods are given on Camry Repair Manual
(Pub. No. RM199U) on page IN-8.
Hydraulic Multiplate ClutchTransfer Front DifferentialCenter
Differential 4-Speed Planetary Gear
Unit and Hydraulic
Control SystemNo. 1 and No. 2 Center Differential
Control Solenoid ValveCenter Differential ControlECT
ECU No. 1 and No. 2 Shift Control
Solenoid Valves and Lock-up
Control solenoid ValveEngine ECU
Throttle Position
Sensor
Stop Light Switch
Vehicle Speed
Sensors
Mode Select Switch
Neutral Start Switch
O/D Main Switch
Center Deff. Control
Switch Shift Control Sectional View
Sensors
- AUTOMATIC TRANSAXLEDescriptionAT-3
Page 23 of 2389
Type of Transmission
A540E
A540H
Type of Engine
2VZ-FE
3S-FE
Torque ConverterStall Torque Ratio
1.9 : 1
2.0 : 1
Lock-Up Mechanism
Equipped
u
Gear Ratio1st Gear
2.810
u
2nd Gear
1.549
u
3rd Gear
1.000
u
O/D Gear
0.734
u
Reverse Gear
2.296
Number of Discs and
Plates (Disc/Plate)C
0O/D Direct Clutch
2/2
u
C
1Forward Clutch 4/4
u
C
2Direct Clutch 3/3
u
B
22nd Brake
3/3
u
B
3First & Reverse Brake 7/7 6/6
B
0O/D Brake
3/3
u
mm (in.)B1 Band Width
38 (1.50)
25 (0.98)
AT FType
ATF DEXRON IIATF Type T or
equivalent
Capacity liter
(US qts, Imp. qts)A/T5.9 (6.2, 5.2)
7.0 (7.4, 6.2)
D/F1.0 (1.1, 0.9)
Transfer OilTypeTransaxle oil E50,
API GL5,
SAE 75W-90
or equivalent
Capacity liter (US qts, Imp. qts)
0.7 (0.7, 0.6)
General Specification
u
AT-4- AUTOMATIC TRANSAXLEDescription
