Toyota 1991 CAMRY Body Section Operating instructions

Pub. Name Pub. No.
’91 Camry Repair Manual RM199U
Automatic Transmission Applicable Model
A540E
A540H ’91 Camry
FOREWORD
This repair manual covers Disassembly, Inspection and As-
sembly procedures for the following Automatic Transaxles:
For On-vehicle Servicing (Inspection, Adjustment, Trouble-
shooting, Removal and Installation) of Automatic Transaxle,
refer to the repair manual for the applicable vehicle model.
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

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:
kg-cm (ft-lb, N-m)
AT3608
♦Non-reusable part : Specified torque
♦O-Ring
♦Oil Seal
Drive Gear
Thrust Washer
Oil Seal Ring
Pump Body Driven Gear Stator Shaft
100 (7, 10)
IN-2 -INTRODUCTION How to Use This Manual

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/cm2, 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.
-INTRODUCTION How to Use This Manual IN-3

IN0036
Seal Lock Adhesive
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
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
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 ”” symbol.
IN-4 -INTRODUCTION GeneralRepair 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.
-INTRODUCTION GeneralRepair Instructions IN-5

ABBREVIATIONS USED IN THIS MANUAL
A/T ATM Automatic Transmission
ATF Automatic Transmission Fluid
B0Overdrive Brake
B1Second Coast Brake
B2Second Brake
B3First and Reverse Brake
C0Overdrive Clutch
C1Forward Clutch
C2Direct 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 -INTRODUCTION AbbreviationsUsed in This Manual

Illustration
09226 - 10010
Part No.
Crankshaft Front &
Rear Bearing Replacer
Part Name
A540H
Note
09240 - 00020 Wire Gauge Set
09308 - 00010 Oil Seal Puller
A540H
09316 - 12010 Transfer Bearing
Replacer
A540H
09316 - 20011 Transfer Bearing
Replacer
09316 - 60010 Transmission &
Transfer Bearing
Replacer
(09316 - 00010) (Replacer Pipe)
(09316 - 00040) (Replacer ”C”)
A540H
(09316 - 00060) (Replacer ”E”)
A540H
09318 - 12010 Transfer Bearing
Adjusting Nut Wrench
A540H
09325 - 12010 Transmission Oil
Plug
A540H
09325 - 20010 Transmission Oil
Plug
A540H
09326 - 20011 Output Shaft Bearing
Lock Nut Wrench
A540H
09330 - 00021 Companion Flange
Holding Tool
A540H
09350 - 32014 TOYOTA Automatic
Transmission Tool
Set
PREPARATION
SST (SPECIAL SERVICE TOOLS)
-AUTOMATIC TRANSAXLE Preparation AT-9

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)
(09351 - 32090) Oil Seal Remover
& Replacer
A540H
(09351 - 32100) Drive Pinion Bearing
Replacer
(09351 - 32111) Side Bearing Race
Replacer
A540H
(09351 - 32120) Overdrive Bearing
Replacer
(09351 - 32140) (Oil Seal Replacer)
(09351 - 32150) (Oil Seal Replacer)
(09351 - 32190) (Measure Terminal)
(09351 - 32200) No. 3 Piston Spring
Compressor
SST (SPECIAL SERVICE TOOLS) (Cont’d)
AT-10 -AUTOMATIC TRANSAXLE Preparation

Illustration Part No. Part Name Note
09502 - 12010 Differential Bearing
Replacer
A540H
09506 - 35010 Differential Drive
Pinion Rear Bearing
Replacer
A540H
09520 - 32012 Differential Side Gear
Shaft Puller
A540H
09608 - 30022 Front Hub Bearing
Replacer Set
A540H
(09550 - 00050) (Replacer)
A540H
(09608 - 05010) (Handle)
A540H
09608 - 32010 Steering Knuckle
Oil Seal Replacer
A540H
09608 - 35014 Axle Hub & Drive
Pinion Bearing
Tool Set
A540H
(09608 - 06020) (Handle)
A540H
(09608 - 06120) Front Hub Outer
Bearing Cup Replacer
A540H
09612 - 65014 Steering Worm
Bearing Puller
Remove pinion shaft Bearing outer race
09950 - 00020 Bearing Remover
A540H
09950 - 00030 Bearing Remover
Attachment
A540H
09950 - 20017 Universal Puller
SST (SPECIAL SERVICE TOOLS) (Cont’d)
-AUTOMATIC TRANSAXLE Preparation AT-11

Illustration Part No. Part Name Note
09031 - 00030 Pin Punch
Part Name Note
Feeler gauge Check major clearance.
Vernier caliper with depth gauge Check length of second coast brake piston rod.
Dial indicator with magnetic base Check piston stroke and end play of the output shaft.
Dial indicator Check inside diameter of major bushing.
Straight edge Check side clearance of oil pump.
Torque wrench
Part Name Part No. Use etc.
Seal packing 1281,
Three bond 1281 or equivalent 08826 - 00090
Transfer right case ×Transfer left case (A540H)
Transfer inspection hole cover (A540H)
Transfer case ×Differential carrier cover
Differential LH bearing retainer (A540E, A540H)
Differential RH retainer (A540E)
Transaxle ×Transfer assembly (A540H)
Adhesive 1324,
Three bond 1324 or equivalent 08833 - 00070
Differential LH bearing retainer set bolt
Differential carrier cover set bolt
Torque converter mounting bolt
Differential RH retainer set bolt (A540E)
Transfer set bolt (A540H)
SSM (SPECIAL SERVICE MATERIALS)
RECOMMENDED TOOL
EQUIPMENT
AT-12 -AUTOMATIC TRANSAXLE Preparation

Mark Class Mark Class
Hexagon
head bolt
4
Bolt
head No.
4-
5-
6-
7-
8-
9-
10-
11-
4T
5T
6T
7T
8T
9T
10T
11T
Stud bolt
No mark
4T
No mark 4T
Grooved
6T
Hexagon
flange bolt
w/ washer
hexagon bolt
No mark 4T
Hexagon
head bolt Two
protruding
lines 5T
Hexagon
flange bolt
w/ washer
hexagon bolt
Two
protruding
lines 6T Welded bolt
4T
Hexagon
head bolt Three
protruding
lines 7T
Hexagon
head bolt Four
protruding
lines 8T
STANDARD BOLT TORQUE SPECIFICATIONS
HOW TO DETERMINE BOLT STRENGTH
B-2 STANDARD BOLT TORQUE SPECIFICATIONS

Class Diameter
mm Pitch mm
Specified torque
Hexagon head bolt Hexagon flange bolt
kg-cm ft-lb N-m kg-cm ft-lb N-m
4T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
5
12.5
26
47
74
115
48 in.-Ib
9
19
35
55
83
55
130
260
480
760
1,150
52 in.-Ib
10
21
39
61
-
60
145
290
540
850
-
6
14
29
53
84
-
5T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
6.5
15.5
32
59
91
140
65
160
330
600
930
1,400
56 in.-Ib
12
24
43
67
101
75
175
360
670
1,050
-
65 in.-lb
13
26
48
76
-
7.5
17.5
36
65
100
-
6T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
8
19
39
71
110
170
69 in.-lb
14
29
53
80
127
80
195
400
730
1,100
1,750
90
210
440
810
1,250
-
78 in.-lb
15
32
59
90
-
9
21
44
80
125
-
7T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
110
260
530
970
1,500
2,300
10.5
25
52
95
145
230
8
19
38
70
108
166
12
28
58
105
165
-
120
290
590
1,050
1,700
-
9
21
43
76
123
-
8T 8
10
12
1.25
1.25
1.25
22
45
80
29
61
110
300
620
1,100
24
50
90
33
68
120
330
690
1,250
9T
8
10
12
1.25
1.25
1.25
34
70
125
25
51
94
340
710
1,300
27
57
105
380
790
1,450
37
78
140
10T 8
10
12
1.25
1.25
1.25
390
800
1,450
38
78
140
28
58
105
31
64
116
430
890
1,600
42
88
155
11T
8
10
12
1.25
1.25
1.25
31
64
116
430
890
1,600
42
87
155
480
990
1,800
47
97
175
35
72
130
SPECIFIED TORQUE FOR STANDARD BOLTS
STANDARD BOLT TORQUE SPECIFICATIONS B-3

Second
coast brake Piston stroke
Piston rod length 2.0 - 3.5 mm
95.2 mm
96.3 mm
0.079 - 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 side
0.07 - 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 mm
0.0028 - 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 thickness
0.0358 - 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
clutch Piston stroke
Flange thickness
1.41 - 1.82 mm
3.00 mm
3.37 mm
0.0555 - 0.0717 in.
0.1181 in.
0.1327 in.
Front
planetary
gear
Maximum
Maximum
STD
Maximum
Sun gear bushing inside diameter
Ring gear flange bushing inside diameter
Planetary pinion gear thrust clearance
22.59 mm
30.08 mm
0.16 - 0.56 mm
0.61 mm
0.8894 in.
1.1842 in.
0.0063 - 0.0220 in.
0.024 in.
Rear
planetary
gear
Planetary pinion gear thrust clearance
STD
Maximum
0.16 - 0.56 mm
0.61 mm
0.0063 - 0.0220 in.
0.024 in.
First and
reverse brake Pack clearance 0.85 - 2.05 mm 0.033 - 0.081 in.
Overdrive
unit Direct clutch piston stroke
Direct clutch bushing inside diameter
Counter drive gear preload
Planetary pinion gear thrust clearance
Maximum
at Starting
STD
Maximum
0.0689 - 0.0980 in.
0.8713 in.
940 - 1,560 g 2.1 - 3.4 lb 9.2 - 15.3 N
1.75 - 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 SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H)

Valve body
spring Spring Free length
mm (in.) Coil outer
diameter
mm (in.)
Total
No. of
coils Color
(Upper valve body)
Second coast modulator valve
B1orifice control valve
Down-shift plug
Throttle valve
Throttle modulator valve
Cut-back valve
No. 1 accumulator control valve
Lock-up relay valve
27.5 (1.083)
24.8 (0.976)
29.8 (1.173)
30.7 (1.209)
21.7 (0.854)
21.8 (0.858)
28.1 (1.106)
26.6 (1.047)
8.9 (0.350)
8.0 (0.315)
8.7 (0.343)
9.2 (0.362)
9.5 (0.374)
6.0 (0.236)
10.6 (0.417)
10.2 (0.402)
14.6
12.0
13.5
9.5
9.5
13.5
13.0
11.5
Brown
White
Yellow
Purple
Orange
Red
Yellow
Green
(Lower valve body)
Pressure relief valve
Check valve
Secondary regulator valve
No. 2 accumulator control valve
Second lock valve
3 - 4 shift valve
Low coast modulator valve
1 - 2 shift valve
2 - 3 shift valve
Primary regulator valve
11.2 (0.441)
19.9 (0.783)
38.5 (1.516)
23.0 (0.906)
20.7 (0.815)
29.2 (1.150)
20.2 (0.795)
29.2 (1.150)
28.0 (1.102)
64.2 (2.528)
6.4 (0.252)
11.0 (0.433)
8.4 (0.331)
6.3 (0.248)
6.1 (0.240)
8.9 (0.350)
7.9 (0.311)
8.9 (0.350)
9.4 (0.370)
18.6 (0.732)
7.5
8.5
17.0
12.0
12.0
12.0
11.9
12.0
10.3
12.5
None
None
Purple
Gray
Orange
Light green
Purple
Light green
None
None
Valve body
retainer Retainer Height
mm (in.) Width
mm (in.) Thickness
mm (in.)
(Upper valve body)
Lock-up relay valve
Throttle modulator valve
Second coast modulator valve
Cut-back valve
No. 1 accumulator control valve
B1orifice control valve
6.5 (0.256)
6.5 (0.256)
6.5 (0.256)
9.2 (0.362)
6.5 (0.256)
11.5 (0.453)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
(Lower valve body)
Primary regulator valve
Secondary regulator valve
No. 2 accumulator control valve
Second lock valve
Low coast modulator valve
1 - 2 shift valve
2 - 3 shift valve
3 - 4 shift valve
9.2 (0.362)
15.0 (0.591)
9.2 (0.362)
11.5 (0.453)
11.5 (0.453)
6.5 (0.256)
9.2 (0.362)
6.5 (0.256)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
5.0 (0.197)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
3.2 (0.126)
Specifications (Cont’d)
-SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) A-3

Accumulator
spring Spring Free length
mm (in.) Coil outer
diameter
mm (in.)
Total
No. of
coils Color
Inner
Outer
C143.4 (1.709)
71.2 (2.803) 17.8 (0.701)
24.4 (0.961) 9.0
11.5
Light Green
Blue
C251.0 (2.008) 18.0 (0.709) 10.2 Red
C0
(O/D case) Inner
Outer
47.5 (1.870)
59.3 (2.335) 18.9 (0.744)
25.5 (1.004) 9.5
9.5
White
Gray
B258.5 (2.303) 15.2 (0.598) 15.9 Orange
B0(Valve body) 62.2 (2.449) 14.8 (0.583) 17.0 None
Differential
Side bearing adjusting shim thickness
Drive pinion preload (at starting)
New Bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
0.0787 in.
0.0807 in.
0.0827 in.
0.0846 in.
0.0866 in.
0.0886 in.
0.0906 in.
0.0925 in.
0.0945 in.
0.0965 in.
0.0984 in.
0.1004 in.
0.1024 in.
0.1043 in.
0.1063 in.
0.1083 in.
0.1103 in.
0.1122 in.
2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
2.25 mm
2.30 mm
2.35 mm
2.40 mm
2.45 mm
2.50 mm
2.55 mm
2.60 mm
2.65 mm
2.70 mm
2.75 mm
2.80 mm
2.85 mm
10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m
5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m
Add drive pinion preload
2.8 - 4.4 kg-cm 2.4 - 3.8 in.-lb 0.3 - 0.4 N-m
1.4 - 2.2 kg-cm 1.2 - 1.9 in.-lb 0.1 - 0.2 N -
0.05 - 0.20 mm 0.0020 - 0.0079 in.
0.80 mm 0.0315 in.
0.90 mm 0.0354 in.
1.00 mm 0.0394 in.
1.10 mm 0.0433 in.
1.20 mm 0.0472 in.
1.30 mm 0.0512 in.
1.40 mm 0.0551 in.
Specifications (Cont’d)
A-4 -SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H)

Second
coast brake Same the A540E automatic transaxle (See page A-2)
Oil pump ↑
Direct clutch Piston stroke
Drum bushing inside diameter Maximum
Flange thickness
1.11 - 1.47 mm
48.27 mm
2.70 mm
3.00 mm
0.0437 - 0.0579 in.
1.9004 in.
0.1063 in.
0.1181 in.
Forward
clutch Same the A540E automatic transaxle (See page A-2)
Front
planetary gear ↑
Rear
planetary gear ↑
First and
reverse brake Pack clearance 0.0409 - 0.0850 in.1.04 - 2.16 mm
Over drive
unit Same the A540E automatic transaxle (See page A-2)
Valve body
spring Same the A540E automatic transaxle (See page A-3)
Valve body
retainer Same the A540E automatic transaxle (See page A-3)
Accumulator
spring Same the A540E automatic transaxle (See page A-4)
Part tightened kg-cm ft-lb N-m
Oil cooler pipe union
Oil pan
Valve body ×Transaxle case
Accumulator ×Cover
Oil pump ×Transaxle case
O/D case ×Transaxle case
Differential LH side bearing retainer
Differential RH retainer
Differential carrier cover
Oil pump body ×Stator shaft
Upper valve body ×Lower valve body
Differential left case ×Right case
Ring gear ×Differential case
275
50
110
100
225
250
195
195
400
100
67
640
1,260
27
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 SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) A-5

Transfer Driven pinion preload (at starting)
Total preload (at starting)
Ring gear backlash
Driven pinion bearing cage
Driven pinion preload (at starting)
New bearing
Reused bearing
Center differential side gear backlash
0.9 - 1.4 kg 2.0 - 3.1 lb 8.8 - 13.7 N
0.5 - 0.9 kg 1.1 - 2.0 lb 4.9 - 8.8 N
0.13 - 0.18 mm 0.0051 - 0.0071 in.
1.8 - 2.9 kg 4.0 - 6.4 lb 18 - 28 N
0.9 - 1.4 kg 2.0 - 3.1 lb 9 - 13 N
0.05 - 0.20 mm 0.0020 - 0.0079
Differential Drive pinion preload (at staring)
New bearing
Reused bearing
Total preload (at starting)
New bearing
Reused bearing
Pinion to side gear backlash
Side gear thrust washer thickness
Mark
A
B
C
D
E
F
G
Side bearing adjusting shim thickness
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
Differential end play
2.00 mm
2.05 mm
2.10 mm
2.15 mm
2.20 mm
2.25 mm
2.30 mm
2.35 mm
2.40 mm
2.45 mm
2.50 mm
2.55 mm
2.60 mm
2.65 mm
2.70 mm
2.75 mm
2.80 mm
2.85 mm
0.18 - 0.82 mm
0.0787 in.
0.0807 in.
0.0827 in.
0.0846 in.
0.0866 in.
0.0886 in.
0.0906 in.
0.0925 in.
0.0945 in.
0.0965 in.
0.0984 in.
0.1004 in.
0.1024 in.
0.1043 in.
0.1063 in.
0.1083 in.
0.1103 in.
0.1122 in.
0.0071 - 0.0323 in.
0.0394 in.
0.0413 in.
0.0433 in.
0.0453 in.
0.0472 in.
0.0492 in.
0.0512 in.
1.00 mm
1.05 mm
1.10 mm
1.15 mm
1.20 mm
1.25 mm
1.30 mm
10 - 16 kg-cm 8.7 - 13.9 in.-lb 1.0 - 1.6 N-m
5 - 8 kg-cm 4.3 - 6.9 in.-lb 0.5 - 0.8 N-m
2.3 - 3.7 kg-cm 2.0 - 3.2 in.-lb 0.2 - 0.4 N-m
1.2 - 1.9 kg-cm 1.0 - 1.6 in.-lb 0.1 - 0.2 N-m
0.05 - 0.20 mm 0.0020 - 0.0079 in.
Specifications (Cont’d)
TRANSFER (A540H)
Specifications
A-6 -SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H)

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 spring Free length
mm (in.)
Coil outer
diameter
mm (in.)
Total
No. of
coils
Color
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve
32.2 (1.272)
28.9 (1.138)
28.9 (1.138)
7.6 (0.299)
7.0 (0.276)
7.0 (0.276)
16
14
14
None
None
None
Transfer lower valve body retainer Height
mm (in.)
Width
mm (in.)
Thickness
mm (in.)
Transfer clutch modulator valve
No. 2 low-high shift valve
No. 1 low-high shift valve
6.5 (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 mm
0.0839 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 SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) A-7

Part tightened kg-cm ft-lb N-m
Oil cooler pipe union and elbow
Oil pan
Valve body ×Transaxle case
Accumulator ×Cover
Oil pump ×Transaxle case
O/D case ×Transaxle case
Differential LH side bearing retainer
Differential carrier cover
Oil pump body ×Stator shaft
Upper valve body ×Lower valve body
Front differential right case ×Front differential left case
Ring gear ×Ring gear mounting case
Transfer right case retainer ×Transfer right case
Transfer right case ×Adjusting nut lock plate lock bolt
Transfer right case ×Transfer left case
Transfer right case ×Mode select lever and rod
275
50
110
100
225
250
195
400
100
67
340
1,260
300
73
450
55
115
20
43 in.-lb
8
7
16
18
14
29
7
58 in.-lb
25
91
22
63 in.-lb
33
48 in.-lb
8
27
4.9
11
10
22
25
19
39
10
6.6
33
124
29
7.2
44
5.4
11
Transfer
(Cont’d) 81
82
83
84
85
86
87
88
89
90
91
92
93
94
Mark
A
B
C
D
E
F
G
H
J
K
Ring gear adjusting shim
2.43 mm
2.46 mm
2.49 mm
2.52 mm
2.55 mm
2.58 mm
2.61 mm
2.64 mm
2.67 mm
2.70 mm
2.73 mm
2.76 mm
2.79 mm
2.82 mm
0.30 mm
0.33 mm
0.36 mm
0.39 mm
0.42 mm
0.45 mm
0.48 mm
0.51 mm
0.54 mm
0.57 mm
0.0957 in.
0.0969 in.
0.0980 in.
0.0992 in.
0.1004 in.
0.1016 in.
0.1028 in.
0.1039 in.
0.1051 in.
0.1063 in.
0.1075 in.
0.1087 in.
0.1098 in.
0.1110 in.
0.0118 in.
0.0130 in.
0.0142 in.
0.0154 in.
0.0165 in.
0.0177 in.
0.0189 in.
0.0201 in.
0.0213 in.
0.0224 in.
Specifications (Cont’d)
Torque Specifications
A-8 -SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H)

Item Capacity Classification
Liters US qts Imp. qts
Automatic
transaxle fluid
(w/o Differential
oil)
A540E
Dry fill
Drain and refill 5.9
2.5
6.2
2.6
5.2
2.2
ATF DEXRONII
A54H
Dry fill
Drain and refill
7.0
3.3
7.4
3.5
6.2
2.9
ATF type T (08886 - 00405) or equivalent
Differential oil
(w/ Automatic transaxle)
SV21 series
VZV21 series
1.6
1.0
1.7
1.1
1.4
0.9
ATF DEXRONII
Transfer oil (A540H) 0.7 0.74 0.62
Recommended oil
Oil grade: API GL-5
Viscosity: SAE 75W-90 or 80W-90
SAE 90W
[above -18°C (0°F)]
SAE 80W
[below -18°C (0°F)]
Transaxle oil E50 (08885 - 80206) or
equivalent
Part tightened kg-cm ft-lb N-m
Transfer right case ×Oil strainer
Transfer left case ×Rear wheel speed sensor
Transfer left case ×Transfer inspection hole cover
Transfer left case ×Drain plug
Transfer left case ×Driven pinion bearing cage
Driven pinion bearing cage ×Transfer extension housing
Transfer extension housing ×Dynamic damper
Transfer right case ×Oil pump cover
Transfer ring gear ×Ring gear mounting case
Center differential control solenoid ×Transfer valve body
Transfer valve body ×Transfer left case
Neutral start switch bolt
Neutral start switch nut
Transfer assembly ×Transaxle case
48 in.-lb
48 in.-lb
12
29
29
19
19
69 in.-lb
71
10
8
48 in.-lb
61 in.-lb
51
55
55
160
400
400
260
260
80
985
145
110
55
70
700
5.4
5.4
16
39
39
25
25
7.8
97
14
11
5.4
6.9
69
Torque Specifications (Cont’d)
LUBRICANT
-SERVICE SPECIFICATIONS Automatic Transaxle Transfer (A540E A540H) A-9