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
1