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FOREWORD
This repair manual covers Disassembly, Inspection and As-
sembly procedures for the following Automatic Transaxles:
Automatic Transmission Applicable Model
A540E '91 Camry
A540H
For On-vehicle Servicing (Inspection, Adjustment, Trouble-
shooting, Removal and Installation) of Automatic Transaxle,
refer to the repair manual for the applicable vehicle model.
Pub. Name Pub. No.
'91 Camry Repair Manual RM199U
All information contained in this manual is the most up-to-data
at the time of publication. However, specifications and proce-
dures are subject to change without notice.
TOYOTA MOTOR CORPORATION
IN-2
INTRODUCTION - How to Use This Manual
HOW TO USE THIS MANUAL
To assist you in finding your way through the manual, the
Section Title and major heading are given at the top of every
page.
An INDEX is provided on the 1st page of each section to
guide you to the item to be repaired.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration.
It identifies the components and shows how the parts fit
together.
Example:
100 (7, 10)
Stator Shaft
Driven Gear
Pump Body
Oil Seal Ring
Thrust Washer
Drive Gear
Oil Seal
O-Ring
kg-cm (ft-lb, N-m) : Specified torque
Non-reusable part
AT3608
IN-3
INTRODUCTION - How to Use This Manual
The procedures are presented in a step-by-step format:
R Illustration shows what to do and where to do it.
R The task heading tells what to do.
R 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
If replacing the disc, plate or flange, check the piston
stroke:
Detail text: how to do it
Illustration:
what to do and where Using a dial indicator (long type pick or SST), measure
the forward clutch piston stroke applying and releasing
the compressed air (4 - 8 kg/cm2, 57 - 114 psi or 392
- 785 kPa) as shown.
SST 09350-32014 (09351-32190)
Set part No. Component part No.
Piston stroke: 1.41 - 1.82 mm (0.0555 - 0.0717 in.)
Specification
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.
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:
R CAUTIONS are presented in bold type, and indicate
there is a possibility of injury to you or other people.
R NOTICES are also presented in bold type, and indicate
the possibility of damage to the components being re-
paired.
R HINTS are separated from the text but do not appear in
bold. They provide additional information to help you effi-
ciently perform the repair.
IN-4
INTRODUCTION - General Repair Instructions
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in order to facilitate
reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative cable four the battery terminal.
(b) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the cable from
the negative (-) terminal which is grounded to the
vehicle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight
up without twisting it or prying it.
(d) Clean the battery terminal posts and cable termi-
nals with a shop rag. Do not scrape them with a file
or other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer or such to tap the terminal onto
the post.
(f) Be sure the cover for the positive (+) terminals are
properly in place.
4. Check hoses and wiring connectors to make sure
that they are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, O-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the "" symbol.
6. Precoated parts
Seal Lock Adhesive Precoated parts are the bolts and nuts, which have
been coated with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated
with the specified adhesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut
IN0036
or installation part threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
(c) Precoated parts are indicated in the component il-
lustrations by the "f" symbol.
IN-5
INTRODUCTION - General Repair Instructions
7. When necessary, use a sealer on gaskets to prevent
leaks.
8. Carefully observe all specifications for bolt tighten-
ing torques. Always use a torque wrench.
9. Use of special service tools (SST) and special ser-
vice materials (SSM) may be required, depending on
the nature of the repair. Be sure to use SST and SSM
where specified and follow the proper work proce-
dure. A list of SST and SSM can be found at the back
of this manual.
10. When replacing fuses, be sure the new fuse has the
correct amperage rating. DO NOT exceed the fuse
amp rating or use one of a lower rating.
11. Care must be taken when jacking up and supporting
the vehicle. Be sure to lift and support the vehicle at
the proper locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any
work on the vehicle raised on jack alone, even for a
small job that can be finished quickly.
IN-6
INTRODUCTION - Abbreviations Used in This Manual
ABBREVIATIONS USED IN THIS MANUAL
A/T ATM Automatic Transmission
ATF Automatic Transmission Fluid
B0 Overdrive Brake
B1 Second Coast Brake
B2 Second Brake
B3 First and Reverse Brake
C0 Overdrive Clutch
C1 Forward Clutch
C2 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
AT-9
AUTOMATIC TRANSAXLE - Preparation
PREPARATION
SST (SPECIAL SERVICE TOOLS)
Illustration Part No. Part Name Note
A540H
Crankshaft Front &
09226 - 10010 Rear Bearing Replacer
09240 - 00020 Wire Gauge Set
A540H
09308 - 00010 Oil Seal Puller
A540H
Transfer Bearing
09316 - 12010 Replacer
Transfer Bearing
09316 - 20011 Replacer
Transmission &
09316 - 60010 Transfer Bearing
Replacer
(09316 - 00010) (Replacer Pipe)
A540H
(09316 - 00040) (Replacer "C")
A540H
(09316 - 00060) (Replacer "E")
A540H
Transfer Bearing
09318 - 12010 Adjusting Nut Wrench
A540H
Transmission Oil
09325 - 12010 Plug
A540H
Transmission Oil
09325 - 20010 Plug
A540H
Output Shaft Bearing
09326 - 20011 Lock Nut Wrench
A540H
Companion Flange
09330 - 00021 Holding Tool
TOYOTA Automatic
09350 - 32014 Transmission Tool
Set
AT-10
AUTOMATIC TRANSAXLE - Preparation
SST (SPECIAL SERVICE TOOLS) (Cont'd)
Illustration Part No. Part Name Note
(09308 - 10010) (Oil Seal Puller)
(09351 - 32032) Counter Driven Gear
Holding Tool
(09351 - 32040) No. 1 Piston Spring
Compressor
(09351 - 32050) (Snap Ring Expander)
(09351 - 32061) (Oil Pump Puller)
(09351 - 32070) No. 2 Piston Spring
Compressor
(09351 - 32080) (Lock Nut Wrench)
A540H
Oil Seal Remover
(09351 - 32090) & Replacer
Drive Pinion Bearing
(09351 - 32100) Replacer
A540H
Side Bearing Race
(09351 - 32111) Replacer
Overdrive Bearing
(09351 - 32120) Replacer
(09351 - 32140) (Oil Seal Replacer)
(09351 - 32150) (Oil Seal Replacer)
(09351 - 32190) (Measure Terminal)
No. 3 Piston Spring
(09351 - 32200) Compressor
AT-1 1
AUTOMATIC TRANSAXLE - Preparation
SST (SPECIAL SERVICE TOOLS) (Cont'd)
Illustration Part No. Part Name Note
A540H
Differential Bearing
09502 - 12010 Replacer
A540H
Differential Drive
09506 - 35010 Pinion Rear Bearing
Replacer
A540H
Differential Side Gear
09520 - 32012 Shaft Puller
A540H
Front Hub Bearing
09608 - 30022 Replacer Set
A540H
(09550 - 00050) (Replacer)
A540H
(09608 - 05010) (Handle)
A540H
Steering Knuckle
09608 - 32010 Oil Seal Replacer
Axle Hub & Drive A540H
09608 - 35014 Pinion Bearing
Tool Set
A540H
(09608 - 06020) (Handle)
A540H
Front Hub Outer
(09608 - 06120) Bearing Cup Replacer
Remove pinion shaft Bearing outer race
Steering Worm
09612 - 65014 Bearing Puller
A540H
09950 - 00020 Bearing Remover
A540H
Bearing Remover
09950 - 00030 Attachment
09950 - 20017 Universal Puller
AT-12
AUTOMATIC TRANSAXLE - Preparation
SSM (SPECIAL SERVICE MATERIALS)
Part Name Part No. Use etc.
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