Camry Repair Manual AUTOMATIC TRANSAXLE

Camry Repair Manual

D00989

O/D Direct

Clutch (C0) O/D Brake (B0)

1st & Reverse Brake (B3)

One – Way clutchNo.2 (F2)

2nd Brake (B2)

ForwardClutch (C1)

2nd Coast brake (B1)Direct Clutch (C2)

O/D One – Way

Clutch (F0)

O/D Planetary Gear

CounterDrive Gear

IntermediateShaft

RearPlanetary Gear

One Way ClutchNo.1 (F1)

Front PlanetaryGear

Input Shaft

Shift lever

position Gear position

ParkingReverseNeutral

*3rd1st

(a) Remove the bolt and vehicle speed sensor assembly

(b) Remove the clip and speedometer driven gear from hicle speed sensor

ve-(c) Remove the O–ring from vehicle speed sensor

(a) Coat a new O–ring with ATF and install it to the vehiclespeed sensor

(b) Install the speedometer driven gear to the vehicle speedsensor and clip

(c) Install the vehicle speed sensor assembly and torque thebolts

Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

ON–VEHICLE REPAIR

(a) Remove the nut and control cable

(b) Remove the nut, washer and control shaft lever

CONNECTOR

(a) Pry off the lock washer and remove the nut

(b) Remove the 2 bolts and park/neutral position switch

(a) Install the park/neutral position switch with 2 bolts

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

(b) Install a new lock plate and the nut

Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)

(c) Bend claws on the lock plate to fix the nut

(d) Adjust the park/neutral position switch

(See page DI–389)

CON-NECTOR

(a) Install the control shaft lever, washer and nut

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

(b) Install the control cable and nut

Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

Some fluid will remain in the oil pan.

Remove the oil pan bolts, and carefully remove the oil pan sembly Discard the gasket

Remove the magnets and use them to collect any steel chips.Look carefully at the chips and particles in the pan and on themagnet to anticipate what type of wear you will find in the trans-axle

Steel (magnetic): bearing, gear and plate wear

Brass (non–magnetic): bushing wear

AND MANUAL VALVE BODY

(a) Remove the detent spring on the manual valve body.(b) Remove the manual valve body

(a) Remove the 3 bolts and the oil strainer

(b) Remove the 2 bolts and oil pipe bracket

NOTICE:

Be careful as oil will come out of the strainer when it is moved.

re-Z10941 AT0493

16 (0.63)

Shift SolenoidValve No.2

AT3008

mm (in.)

AX–6

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AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY

Pry up the both pipe ends with a large screwdriver and removethe 4 pipes

NOTICE:

Be careful not to bend or damage the pipe.

Remove the 12 bolts

(a) Disconnect the throttle cable

(b) Remove the valve body

(a) Remove the 2 bolts and shift solenoid valve No.1.(b) Remove the bolt and shift solenoid valve No.2

(c) Remove the 2 O–rings from the shift solenoid valve No.1and No.2

Shift Solenoid Valve No.2

Black

WhiteShift Solenoid Valve No.1

–

AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY

AX–7

(a) Coat 2 new O–rings with ATF

(b) Install the 2 O–rings to the shift solenoid valve No.1 andNo.2

(c) Install the shift valve No.1 with the 2 bolts

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

(d) Install the shift valve No.2 with the bolt

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

(a) While holding the cam down by your hand, slip the cableend into the slot

NOTICE:

Do not entangle the solenoid wire.

(b) Install the valve body with the 12 bolts

HINT:

Temporarily install the 12 bolts first, then tighten the 12 bolts

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Bolt length:

Bolt A: 20 mm (0.79 in.) Bolt B: 25 mm (0.98 in.) Bolt C: 36 mm (1.42 in.) Bolt D: 50 mm (1.97 in.)

Using a plastic hammer, install the 4 pipes into the positions dicated in the illustration

in-NOTICE:

Be careful not to bend or damage the pipes.

Connect the black wire harness to shift solenoid valve No.2 andwhite wire harness to shift solenoid valve No.1

AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY

(a) Install the 2 bolts and oil pipe bracket

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

(b) Install the 3 bolts and oil strainer

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

AND MANUAL VALVE BODY

(a) Align the manual valve with the pin on the manual shaftlever

(b) Lower the manual valve body into place

(c) Temporarily install the 4 bolts first Then, tighten them with

(e) Check that the manual valve lever is touching the center

of the detent spring tip roller

NOTICE:

Make sure that the magnets do not interfere with the oil pipes.

Install a new gasket and oil pan with the 15 bolts

Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

(a) Disconnect the cable from the throttle linkage.

(b) Disconnect the cable from the cable clamps in the enginecompartment

(See page AX–4)

(a) Remove the retaining bolt and plate

(b) Pull out the cable from the transaxle case

PAINT MARK ON INNER CABLE

HINT:

New cable does not have a staked cable stopper

(a) Bend the cable to ensure a radius of about 200 mm (7.87in.)

(b) Pull the inner cable lightly until a slight resistance is felt,and hold it there

(c) Stake the stopper, 0.8 – 1.5 mm (0.031 – 0.059 in.) fromthe end of the outer cable

(d) Install a new O–ring to the throttle cable

(e) Push in the throttle cable and install the retaining bolt

(See page AX–4)

AX03A–01

AX–10

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AUTOMATIC TRANSAXLE (A140E) SHIFT SOLENOID VALVE SL

SHIFT SOLENOID VALVE SL

ON–VEHICLE REPAIR

(See page AX–4)

CONNEC-TOR

(a) Remove the 2 bolts and shift solenoid valve SL

(b) Remove the 2 O–rings from the shift solenoid valve SL

(a) Coat 2 new O–rings with ATF and install them to the shiftsolenoid valve SL

(b) Install the shift solenoid valve SL and 2 bolts

(See page AX–4)

Using SST, drive out the oil seals on both sides.

SST 09308–00010

(a) Using SST, drive in a new oil seal

SST 09350–32014 (09351–32130, 09351–32150)

Oil seal depth:

(b) Coat the lip of oil seal with MP grease

D00760

Shift Lock Override Cover

Shift Lock Override Button

Stop Light Switch

Key Interlock Solenoid

Shift LockControl Unit Assembly

AX–12

–

AUTOMATIC TRANSAXLE (A140E) SHIFT LOCK SYSTEM (TMC Made)

SHIFT LOCK SYSTEM (TMC Made)

LOCATION

Using a voltmeter, measure the voltage at each terminal.HINT:

Do not disconnect the shift lock control unit assembly tor

4 – 3 (KLS + – E)

(1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx 1 second)

0 7.5 – 11

6 – 9.5

(a) Disconnect the solenoid connector

(b) Using an ohmmeter, measure resistance between nals

If resistance value is not as specified, replace the solenoid

(c) Apply battery positive voltage between terminals Checkthat an operation noise can be heard from the solenoid

If the solenoid does not operate, replace the solenoid

D00759

Shift Lock Override Cover

Shift Lock Override Button

Shift Lock Solenoid

Shift Lock Control SwitchShift Lock Control ECU

Key Interlock Solenoid

Stop Light Switch

AX–14

–

AUTOMATIC TRANSAXLE (A140E) SHIFT LOCK SYSTEM (TMMK Made)

SHIFT LOCK SYSTEM (TMMK Made)

LOCATION

Using a voltmeter, measure voltage at each terminal.

HINT:

Do not disconnect the ECU connector

A, 6 – A, 5 (STP – E) Depressing brake pedal 10 – 14

A, 4 – A, 5 (KLS + – E)

(1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx 1 second)

0 7.5 – 11

B, 3 – B, 1 (P1 – P) (1) Ignition switch ON, P position and depressing brake pedal

(2) Shift except P position under conditions above

0

9 – 13.5

B, 4 – B, 1 (P2 – P) (1) Ignition switch ACC, P position

(2) Shift except P position under conditions above

9 – 13.5 0

(a) Disconnect the solenoid connector

(b) Using an ohmmeter, measure resistance between nals

If resistance value is not as specified, replace the solenoid

(c) Apply battery positive voltage between terminals Checkthat operation noise can be heard from the solenoid

If the solenoid does not operate, replace the solenoid

AUTOMATIC TRANSAXLE (A140E) SHIFT LOCK SYSTEM (TMMK Made)

(a) Disconnect the solenoid connector

(b) Using an ohmmeter, measure resistance between nals

If resistance value is not as specified, replace the solenoid

(c) Apply battery positive voltage between terminals Checkthat an operation noise can be heard from the solenoid

If the solenoid does not operate, replace the solenoid

Inspect that there is continuity between each terminal

Shift position Tester connection Specified value

P position (Release button is not pushed) 1 – 3 (P – P1) Continuity

P position (Release button is pushed)

Snap Ring

LH Drive Shaft

Plug for Line Pressure Test

Rear End Plate

Front Exhaust Pipe

RH Front Lower Brace

Green Color Bolt : 66 (670, 48) Silver Color Bolt : 44 (450, 32)

TMC Made : 80 (820, 59)

TMMK Made :

Green Color Bolt : 66 (670, 48)

Silver Color Bolt : 44 (450, 32)

LH FrontLower Brace

Tie Rod End

Lock Nut Cap

Engine Under Cover

Clamp LH Fender Liner

LH Fender Apron Seal

REMOVE CRUISE CONTROL ACTUATOR

(a) Disconnect the connector

(b) Remove the 3 bolts and disconnect cruise control tor with the bracket

Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (450 kgf·cm, 32 ft·lbf)

(a) Disconnect the connector and remove the nut

(b) Remove the 2 bolts, shift cable clamp and starter

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

Torque: 66 N·m (670 kgf·cm, 48 ft·lbf)

AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE UNIT

Remove the 2 bolts and exhaust manifold stay

Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Torque: 66 N·m (670 kgf·cm, 48 ft·lbf)

(a) Disconnect the washer pipe

(b) Remove the 4 bolts and engine hood

Torque: 14 N·m (145 kgf·cm, 10 ft·lbf)

Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

EN-GINE UNDER COVER

(a) Remove the nut and disconnect the shift control cablefrom the park/neutral position switch

(a) Remove the 2 nuts and exhaust front pipe clamp.

TMC made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK made:

Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (450 kgf·cm, 32 ft·lbf)

(a) Remove the 2 grommets

(b) Remove the 3 nuts

Torque: 66 N·m (670 kgf·cm, 48 ft·lbf)

(a) Remove the 2 grommets

(b) Remove the 2 nuts

Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE UNIT

(a) Remove the 4 bolts, LH and RH stabilizer bar bracketsand bushings

Torque:19 N·m (195 kgf·cm, 14 ft·lbf)

(b) Remove the front stabilizer bar (See page SA–48)(c) Remove the 2 steering gear housing mounting bolts andnuts

Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)

MOUNTING BRACKET BY CORD OR EQUIVALENT

HANG-ERS CAUTION:

Do not attempt to hang the engine by hooking the chain to any other part.

(a) Remove the 2 bolts and steering return pipe mountingbrackets

(e) Remove the front frame assembly.

(a) Remove the 2 bolts and No.1 exhaust pipe support et

brack-Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

(b) Remove the 2 bolts and rear end plate with oil pan tor

insula-Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

AX–24

–

AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE UNIT

(a) Remove the 2 bolts and manifold stay

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

(b) Remove the 4 bolts and stiffener plate

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

Separate the transaxle and engine, and lower the transaxle

After installation, check and inspect items as follows.

Fluid level (See page DI–389)

Front wheel alignment (See page SA–4)

Road test of the vehicle

Engine hood (See page BO–10)

AUTOMATIC TRANSAXLE (A140E) TORQUE CONVERTER CLUTCH AND DRIVE PLATE

TORQUE CONVERTER CLUTCH AND DRIVE PLATE

INSPECTION

(a) Install SST into the inner race of the one–way clutch.SST 09350–32014 (09351–32010)

(b) Install SST so that it fits in the notch of the converter huband outer race of the one–way clutch

SST 09350–32014 (09351–32020)

(c) With the torque converter clutch standing on its side,theclutch locks when turned counterclockwise, and rotatesfreely and smoothly clockwise

If necessary, clean the converter and retest the clutch Replacethe converter clutch if the clutch still fails the test

RING GEAR

Set up a dial indicator and measure the drive plate runout

Maximum runout: 0.20 mm (0.0079 in.)

If the runout is not within the specification or if the ring gear isdamaged, replace the drive plate If installing a new drive plate,note the orientation of spacers and tighten the bolts

Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

Maximum runout: 0.30 mm (0.0118 in.)

If the runout is not within the specification, try to correct by enting the installation of the torque converter clutch If exces-sive runout cannot be corrected, replace the torque converterclutch

O/D Brake (B0)

2nd Coast Brake(B1)

Intermediate Shaft

1st and ReverseBrake (B3)

One–Way ClutchNo.2 (F2)

Planetary Gear Unit

O/D Planetary Gear

Counter DriveGear

Front Planetary GearRear Planetary Gear

One–Way ClutchNo.1 (F1) Input Shaft

Direct Clutch(C2)

O/D One–Way Clutch

*3rd1st

AX03N–01

Q04678

ClipO–Ring

CONNEC-TOR

(a) Remove the bolt and vehicle speed sensor assembly

(b) Remove the clip and driven gear from the vehicle speedsensor

(c) Remove the O–ring from the vehicle speed sensor

(a) Coat a new O–ring with ATF and install it to the vehiclespeed sensor

(b) Install the driven gear to the vehicle speed sensor andclip

(c) Install the vehicle speed sensor assembly with the bolt

Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

AUTOMATIC TRANSAXLE (A541E) DIRECT CLUTCH SPEED SENSOR

DIRECT CLUTCH SPEED SENSOR

ON–VEHICLE REPAIR

CONNECTOR

(a) Remove the bolt and direct clutch speed sensor

(b) Remove the O–ring from direct clutch speed sensor

(a) Coat a new O–ring with ATF and install it to the directclutch speed sensor

(b) Install the direct clutch speed sensor with the bolt

Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

ON–VEHICLE REPAIR

CONNECTOR

(a) Remove the clip from the shift control cable

(b) Remove the nut and control cable

(c) Remove the nut, washer and transaxle control shaft lever.(d) Using a screwdriver, pry off the lock plate

(e) Remove the nut and lock plate

(f) Remove the 2 bolts and pull out the park/neutral positionswitch

NeutralBasicLine

AUTOMATIC TRANSAXLE (A541E) PARK/NEUTRAL POSITION (PNP) SWITCH

(d) Adjust the park/neutral position switch

(See page DI–438)

(e) Install the transaxle control shaft lever and washer.(f) Install and torque the nut

Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

(g) Install the control cable and nut

Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

(h) Install the clip to the shift control cable

CON-NECTOR

Some fluid will remain in the oil pan.

Remove oil pan bolts, and carefully remove the pan assembly.Discard the gasket

Remove the magnets and use them to collect any steel chips.Look at the chips and particles in the pan and magnet carefully

to anticipate what type of wear you will find in the transaxle

Steel (magnetic): bearing, gear and plate wear

Brass (non–magnetic): bushing wear

(a) Remove the 3 bolts and oil strainer

NOTICE:

Be careful as oil will come out of the strainer when it is moved.

re-(b) Remove the 3 bolts and apply pipe bracket

Pry up both pipe ends with a large screwdriver and remove the

5 pipes

AUTOMATIC TRANSAXLE (A541E) VALVE BODY ASSEMBLY

(a) Remove the 2 bolts and detent spring

(b) Remove the bolt

(c) Pry up the pipe with a screwdriver and remove the pipe

Remove the 5 bolts and manual valve body

Remove the 2 bolts, connector clamp and pipe retainer

Pry up the pipe with a screwdriver and remove the pipe

(a) Remove the 9 bolts