Camry Repair Manual AUTOMATIC TRANSAXLE

Camry Repair Manual

AX034–01 –AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE SYSTEM AX–1 1894A uthorĂ: DateĂ: AUTOMATIC TRANSAXLE SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. AX035–01 D00989 O/D Direct Clutch (C 0 ) O/D Brake (B 0 ) 1st & Reverse Brake (B 3 ) One – Way clutch No.2 (F 2 ) 2nd Brake (B 2 ) Forward Clutch (C 1 ) 2nd Coast brake (B 1 ) Direct Clutch (C 2 ) O/D One – Way Clutch (F 0 ) O/D Planetary Gear Counter Drive Gear Intermediate Shaft Rear Planetary Gear One Way Clutch No.1 (F 1 ) Front Planetary Gear Input Shaft Shift lever position Gear position Parking Reverse Neutral P R N C 1 B 2 B 3 F 0 C 0 C 2 B 0 B 1 F 1 F 2 D 2 L 1st 2nd 3rd O/D 1st 2nd *3rd 1st *2nd z z z z z z z z z z z z z z z z z z z z z z zz z z zz zz zzz z z z z z z z zz z z z z z z z Planetary Gear Unit z: Operating *: Down–shift only in the 3rd gear for the 2 position and 2nd gear for the L position no up–shift. AX–2 –AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE SYSTEM 1895A uthorĂ: DateĂ: OPERATION Q00207 AX036–01 Q04678 Drive Gear Vehicle Speed Sensor O–Ring Clip –AUTOMATIC TRANSAXLE (A140E) VEHICLE SPEED SENSOR AX–3 1896AuthorĂ: DateĂ: VEHICLE SPEED SENSOR ON–VEHICLE REPAIR 1. REMOVE AIR CLEANER ASSEMBLY 2. DISCONNECT VEHICLE SPEED SENSOR CONNEC- TOR 3. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and vehicle speed sensor assembly. (b) Remove the clip and speedometer driven gear from ve- hicle speed sensor. (c) Remove the O–ring from vehicle speed sensor. 4. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new O–ring with ATF and install it to the vehicle speed sensor. (b) Install the speedometer driven gear to the vehicle speed sensor and clip. (c) Install the vehicle speed sensor assembly and torque the bolts. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) 5. CONNECT VEHICLE SPEED SENSOR CONNECTOR 6. INSTALL AIR CLEANER ASSEMBLY Q10050 AX037–01 AX–4 –AUTOMATIC TRANSAXLE (A140E) PARK/NEUTRAL POSITION (PNP) SWITCH 1897AuthorĂ: DateĂ: PARK/NEUTRAL POSITION (PNP) SWITCH ON–VEHICLE REPAIR 1. REMOVE CONTROL SHAFT LEVER (a) Remove the nut and control cable. (b) Remove the nut, washer and control shaft lever. 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Pry off the lock washer and remove the nut. (b) Remove the 2 bolts and park/neutral position switch. 4. INSTALL 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) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CON- NECTOR 6. INSTALL CONTROL SHAFT LEVER (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) AX038–01 Q00073 AT0103 Z10944 mm (in.) 14 (0.551) 36 (1.417) AT2711 Z10940 20 (0.787) mm (in.) 45 (1.772) 50 (1.969) AT3336 –AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY AX–5 1898A uthorĂ: DateĂ: VALVE BODY ASSEMBLY ON–VEHICLE REPAIR 1. DRAIN TRANSAXLE FLUID 2. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the oil pan bolts, and carefully remove the oil pan as- sembly. Discard the gasket. 3. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the trans- axle. z Steel (magnetic): bearing, gear and plate wear z Brass (non–magnetic): bushing wear 4. REMOVE MANUAL VALVE BODY DETENT SPRING AND MANUAL VALVE BODY (a) Remove the detent spring on the manual valve body. (b) Remove the manual valve body. 5. REMOVE OIL STRAINER AND OIL PIPE BRACKET (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 re- moved. Z10941 AT0493 AT7868 AT0399 OR0038 Z19291 16 (0.63) Shift Solenoid Valve No.1 16 (0.63) Shift Solenoid Valve No.2 AT3008 mm (in.) AX–6 –AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY 1899A uthorĂ: DateĂ: 6. DISCONNECT SOLENOID CONNECTORS 7. REMOVE OIL PIPES Pry up the both pipe ends with a large screwdriver and remove the 4 pipes. NOTICE: Be careful not to bend or damage the pipe. 8. REMOVE VALVE BODY Remove the 12 bolts. 9. REMOVE THROTTLE CABLE (a) Disconnect the throttle cable. (b) Remove the valve body. 10. REMOVE 2ND BRAKE APPLY GASKET 11. REMOVE SHIFT SOLENOID VALVE NO.1 AND NO.2 (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.1 and No.2. OR0038 Z10942 C D B A C B A B AT0492 AT7870 Z10941 AT0493 Shift Solenoid Valve No.2 Black White Shift Solenoid Valve No.1 –AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY AX–7 1900A uthorĂ: DateĂ: 12. INSTALL SHIFT SOLENOID VALVE NO.1 AND NO.2 (a) Coat 2 new O–rings with ATF. (b) Install the 2 O–rings to the shift solenoid valve No.1 and No.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) 13. INSTALL NEW 2ND BRAKE APPLY GASKET 14. INSTALL VALVE BODY (a) While holding the cam down by your hand, slip the cable end 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.) 15. INSTALL OIL PIPES Using a plastic hammer, install the 4 pipes into the positions in- dicated in the illustration. NOTICE: Be careful not to bend or damage the pipes. 16. CONNECT SOLENOID CONNECTORS Connect the black wire harness to shift solenoid valve No.2 and white wire harness to shift solenoid valve No.1. Z10940 mm (in.) 20 (0.78) 45 (1.772) 50 (1.969) AT3336 Z10944 mm (in.) 36 (1.417) 14 (0.551) AT2711 Z10945 Magnets AT2368 Q00073 AX–8 –AUTOMATIC TRANSAXLE (A140E) VALVE BODY ASSEMBLY 1901A uthorĂ: DateĂ: 17. INSTALL OIL STRAINER AND OIL PIPE BRACKET (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) 18. INSTALL MANUAL VALVE BODY DETENT SPRING AND MANUAL VALVE BODY (a) Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Temporarily install the 4 bolts first. Then, tighten them with a torque wrench. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (d) Place the detent spring on the manual valve body and temporarily install the 2 bolts first. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (e) Check that the manual valve lever is touching the center of the detent spring tip roller. 19. INSTALL MAGNETS IN OIL PAN NOTICE: Make sure that the magnets do not interfere with the oil pipes. 20. INSTALL OIL PAN AND GASKET Install a new gasket and oil pan with the 15 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 21. FILL FLUID AND CHECK FLUID LEVEL (See page DI–389) AX039–01 Q10052 Q10339 0.8 – 1.5 mm(0.031 – 0.059 in.) 200 mm (7.87 in.) –AUTOMATIC TRANSAXLE (A140E) THROTTLE CABLE AX–9 1902AuthorĂ: DateĂ: THROTTLE CABLE ON–VEHICLE REPAIR 1. DISCONNECT THROTTLE CABLE (a) Disconnect the cable from the throttle linkage. (b) Disconnect the cable from the cable clamps in the engine compartment. 2. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–4) 3. REMOVE VALVE BODY (See page AX–5) 4. REMOVE THROTTLE CABLE (a) Remove the retaining bolt and plate. (b) Pull out the cable from the transaxle case. 5. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR 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 (7.87 in.). (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.) from the 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. 6. INSTALL VALVE BODY (See page AX–5) 7. INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX–4) 8. CONNECT THROTTLE CABLE 9. FILL FLUID AND CHECK FLUID LEVEL (See page DI–389) 10. ADJUST THROTTLE CABLE (See page DI–389) Q10051 AX03A–01 AX–10 –AUTOMATIC TRANSAXLE (A140E) SHIFT SOLENOID VALVE SL 1903A uthorĂ: DateĂ: SHIFT SOLENOID VALVE SL ON–VEHICLE REPAIR 1. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–4) 2. DISCONNECT SHIFT SOLENOID VALVE SL CONNEC- TOR 3. REMOVE SHIFT SOLENOID VALVE SL (a) Remove the 2 bolts and shift solenoid valve SL. (b) Remove the 2 O–rings from the shift solenoid valve SL. 4. INSTALL SHIFT SOLENOID VALVE SL (a) Coat 2 new O–rings with ATF and install them to the shift solenoid valve SL. (b) Install the shift solenoid valve SL and 2 bolts. 5. CONNECT SHIFT SOLENOID VALVE SL CONNECTOR 6. INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX–4) [...]... (b) Remove the torque converter clutch AuthorĂ: DateĂ: 1920 AX–1 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX03L–01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section AuthorĂ: DateĂ: 1921 AX–2 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE SYSTEM AX03M–01 OPERATION 1st and Reverse 2nd Coast Brake... REMOVE TRANSAXLE ASSEMBLY Separate the transaxle and engine, and lower the transaxle AuthorĂ: DateĂ: 1917 AX–25 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AX03I–01 INSTALLATION 1 AT3412 CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using a scale and a straight edge, measure to the distance from the installed surface to the transaxle housing Correct distance: 13.0 mm (0.512 in.) or more 2 TRANSAXLE. .. P2) Continuity R, N, D, 2, L position Q09464 Tester connection 1 – 4 (P – P2) Continuity If continuity is not as specified, replace the switch AuthorĂ: DateĂ: 1909 AX–17 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX03G–01 COMPONENTS 14 (145, 10) Air Cleaner Assembly Engine Hood 14 (145, 10) Starter Hold Down Clamp Cruise Control Actuator RH Drive Shaft Torque Converter... starter Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) REMOVE 3 TRANSAXLE TO–ENGINE BOLTS Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) Q10056 13 Q10057 AuthorĂ: DateĂ: 1912 AX–20 AUTOMATIC TRANSAXLE (A140E) Q10058 – AUTOMATIC TRANSAXLE UNIT 14 REMOVE EXHAUST MANIFOLD STAY Remove the 2 bolts and exhaust manifold stay Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 15 REMOVE TRANSAXLE TO–ENGINE BOLT Torque: 66 N·m (670 kgf·cm,... fender liners Q06479 Q10041 Q10037 AuthorĂ: DateĂ: 1915 AX–23 AUTOMATIC TRANSAXLE (A140E) (d) Front (e) 33 – AUTOMATIC TRANSAXLE UNIT Remove the 6 bolts and 4 nuts Torque: 19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf) 14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut: 36 N·m (370 kgf·cm, 27 ft·lbf) Remove the front frame assembly SUPPORT TRANSAXLE WITH A TRANSMISSION JACK Q10172 Rear Q10064 TMC... SHAFTS (See page SA–24) CHECK TRANSAXLE FLUID LEVEL (See page DI–389) AuthorĂ: DateĂ: 1904 AX–12 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMC Made) SHIFT LOCK SYSTEM (TMC Made) AX03C–01 LOCATION Shift Lock Override Cover Shift Lock Override Button Stop Light Switch Key Interlock Solenoid Shift Lock Control Unit Assembly D00760 AuthorĂ: DateĂ: 1905 AX–13 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK... Remove the 2 grommets Remove the 3 nuts Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) 28 (a) (b) REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT Remove the 2 grommets Remove the 2 nuts Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) Q08532 Q10061 AuthorĂ: DateĂ: 1914 AX–22 AUTOMATIC TRANSAXLE (A140E) 29 (a) (b) (c) – AUTOMATIC TRANSAXLE UNIT REMOVE STEERING GEAR HOUSING Remove the 4 bolts, LH and RH stabilizer bar brackets and... No.1 Exhaust Pipe Support Bracket Rear End Plate 25 (250, 18) Oil Pan Insulator N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part Q10053 AuthorĂ: DateĂ: 1910 AX–18 AUTOMATIC TRANSAXLE (A140E) RH Fender Apron seal – AUTOMATIC TRANSAXLE UNIT RR Engine Mounting Stabilizer Bar TMC Made : 80 (820, 59) TMMK Made : Green Color Bolt : 66 (670, 48) Silver Color Bolt : 44 (450, 32) 19 (195, 14) RH Rear... (3,000, 217) Lock Nut Cap Center Engine Under Cover LH Fender Liner Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part Q10054 AuthorĂ: DateĂ: 1911 AX–19 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AX03H–01 REMOVAL 1 2 3 REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY DISCONNECT THROTTLE CABLE 4 w/ CRUISE CONTROL: REMOVE CRUISE CONTROL ACTUATOR Disconnect the connector... support bracket Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (b) Remove the 2 bolts and rear end plate with oil pan insulator Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) AuthorĂ: DateĂ: 1916 AX–24 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT 36 Q10066 REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley set bolt . Non–reusable part AX–18 AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE UNIT 1911A uthorĂ: DateĂ: AX03H–01 Q10055 Q00211 Q10056 Q10057 AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE UNIT AX–19 1912A. up–shift. AX–2 AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE SYSTEM 1895A uthorĂ: DateĂ: OPERATION Q00207 AX036–01 Q04678 Drive Gear Vehicle Speed Sensor O–Ring Clip AUTOMATIC TRANSAXLE (A140E). ft·lbf) : Specified torque z Non–reusable part TMMK TMC AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE UNIT AX–17 1910A uthorĂ: DateĂ: AUTOMATIC TRANSAXLE UNIT COMPONENTS Q10054 RH Fender Apron seal RR