TOYOTA A540E

TOYOTA A540E
INDEX
GENERAL DESCRIPTION .........................................................................
3
GENERAL TROUBLE-SHOOTING ............................................................
9
COMPONENT APPLICATION CHART .....................................................
11
WIRING SCHEMATIC ................................................................................. 16
EXPLODED TRANSAXLE VIEWS ............................................................. 18
TRANSAXLE DISASSEMBLY ................................................................... 22
COMPONENT INSPECTION AND ASSEMBLY ........................................ 35
VALVE BODY INSPECTION AND ASSEMBLY ......................................... 61
FINAL DRIVE INSPECTION AND ASSEMBLY ......................................... 71
TRANSAXLE ASSEMBLY ......................................................................... 80
CHECK BALL LOCATIONS ....................................................................... 96
CHECKING TRANSAXLE FREEWHEELS ................................................. 99
UPDATED COMMON SUMP CASE DIFFERENCES ............................... 102
HIGH OR LOW LINE PRESSURE CONCERNS ...................................... 106
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 SW 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
Copyright © ATSG 2003
Updated
January, 2004
INTRODUCTION
TOYOTA A540E
The Toyota A540E is an automatic overdrive transaxle that is found in the V-6 Camery model vehicles. It is an
electronic controlled transaxle and very similar to the A140. We have included a section on the basic operation,
diagnosis, disassembly, reassembly of this unit along with a section on some of the updates and changes that
have occured.
We wish to thank Toyota
for the information and illustrations
that have made this booklet possible.
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.
The information and part numbers contained in this booklet have
been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 2003
DALE ENGLAND
JIM DIAL
FIELD SERVICE CONSULTANT
TECHNICAL CONSULTANT
WAYNE COLONNA
ED KRUSE
TECHNICAL SUPERVISOR
TECHNICAL CONSULTANT
PETER LUBAN
GREGORY LIPNICK
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
JON GLATSTEIN
DAVID CHALKER
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
ROLAND ALVAREZ
JERRY GOTT
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
GERALD CAMPBELL
MIKE SOUZA
TECHNICAL CONSULTANT
TECHNICAL CONSULTANT
AUTOMATIC TRANSMISSION SERVICE GROUP
18639 SW 107TH AVENUE
MIAMI, FLORIDA 33157
(305) 670-4161
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