Toyota A540 / A541 FWD 4 Speed

20
45
50 52
51
10

Stator Direct Drum

Pump Body

54 54 70
53

B
Sun
Forward Gear Intermediate
Planet Sprag
Shell

36 37

1st / Reverse Clutch

Park Pawl
14
Linkage
E
Intermediate
Servo
2
Filter 80
Accumulator
Assembly
81
1 150

Shift Solenoids

Valve 90
Body
TCC Solenoid

91
2013.1.0
13.4-1
FWD 4 Speed Toyota A540 / A541
31 33
30 32
21

Forward Drum
Direct Clutch Forward Clutch
34 35
71

B
Rear Ring
Rear Planetary Rear Planet Gear
2nd Clutch Sprag

12
11

105
Differential
13 13 100

D
Pinion
22
72

E
Overdrive
Overdrive Planet Sprag
38 39 41
40

Overdrive Direct
Overdrive Brake Clutch Clutch
23
55
56

G
3

Overdrive
Overdrive Cover
Direct Drum
2013.1.0
13.4-2
 Toyota A540E/H, A541E (FWD 4-Speed)
VEHICLE ENGINE TRANS.
MODEL YEARS TYPE

Avalon ............................................ 1995-04 ............................... V6 (3.0 Litre DOHC) ........................ A541E

Camry ............................................. 1988-91 ............................... V6 (2.5 Litre) ....................................A540E
1992-93 ............................... V6 (3.0 Litre) ....................................A540E
1994-01 ............................... V6 (3.0 Litre DOHC) ........................ A541E
Camry (AWD) ................................. 1989-91 ............................... 4 Cylinder ....................................... A540H
RAV4 (AWD) ................................... 1996-00 ............................... 4 Cylinder ....................................... A540H
Sienna ............................................ 1998-00 ............................... 6 Cylinder ........................................ A540E
........................................................ 2001-03 ............................... 6 Cylinder ........................................ A541E
Solara ............................................. 1998-03 ............................... 6 Cylinder ........................................ A541E
ES250 ............................................. 1989-91 ............................... V6 (2.5 Litre) ....................................A540E
ES300 ............................................. 1992-93 ............................... V6 (3.0 Litre DOHC) ........................ A540E
1994-01 ............................... V6 (3.0 Litre DOHC) ........................ A541E
ILL. PART PER
NO. NUMBER CAR DESCRIPTION YEARS

MASTER BOX KITS

--- K8300-S 1 Master Kit (w/o Steels) ......................................... A540E/H .......................................... 1988-91
--- K8300A-S Master Kit (w/o Steels) ........................................... A540E ............................................ 1992-00
--- K8300C-S Master Kit (w/o Steels) ........................................... A541E ............................................ 1994-04
--- K8300E-S 1 Master Kit (w/o Steels) ..................................... A540H - RAV4 ...................................... 1996-00
--- K8300T-S Master Kit (w/o Steels) ....................... A540H - Transfer Case Section ........................ 1989-00

--- K8300-9 1 Steel Plate Kit ...................................................... A540E/H .......................................... 1988-91

--- K8300A-9 Steel Plate Kit ........................................................ A540E ............................................ 1992-00
--- K8300C-9 Steel Plate Kit ........................................................ A541E ......................................... 1994-5/97
--- K8300F-9 Steel Plate Kit ........................................................ A541E ............................................. 6/97-04
--- K8300E-9 1 Steel Plate Kit .................................................. A540H - RAV4 ...................................... 1996-00
--- K8300T-9 Steel Plate Kit .................................... A540H - Transfer Case Section ........................ 1989-00
1
Kits do not include parts for Transfer Case sections on AWD units, please order these separately.

OVERHAUL KITS, GASKET SETS AND GASKETS

--- K83900 1 Overhaul Kit (Transmission Section) .................. A540E/H .......................................... 1988-00
--- K83900C 1 Overhaul Kit (Transmission Section) ................... A541E ............................................ 1994-04
--- K83900T 1 Overhaul Kit (Transfer Case Section) .................. A540H ............................................ 1989-00
1E 83170 1 Oil Pan Gasket .......................................... Duraprene - A540E/H ................................ 1988-00
1E 83170C 1 Oil Pan Gasket ............................................ Duraprene - A541E .................................. 1994-04
2E 83120 1 Oil Filter Gasket .................................................... A540E/H .......................................... 1988-00
2E 83120C 1 Oil Filter Gasket ..................................................... A541E ............................................ 1994-04
--- 81100 1 Pump O’Ring ........................................................ A540E/H .......................................... 1988-00
--- 83100C 1 Pump O’Ring ......................................................... A541E ............................................ 1994-04
3G 83110 1 O/D Cover Gasket ................................................ A540E/H .......................................... 1988-00
3G 83110C 1 O/D Cover Gasket ................................................. A541E ............................................ 1994-04

METAL CLAD SEALS

10A 67526A 1 Front Pump ................................................................ All ............................................... 1988-04
11C 83551 1 Right Axle (40x56x9mm) .......................................... All ............................................... 1988-04
12C 83552A 1 Left Axle (50x80x16.5mm) .............................. A540E / A541E ..................................... 1988-04
12C 83552B 1 Left Axle (AWD) ...................................................... A540H ............................................ 1989-00
--- 83553 1 Extension Housing (AWD) .................................... A540H ............................................ 1989-00
13D 83554 2 Pinion ............................................................................................................................. 1988-04
14D 68504 1 Manual Lever .................................................................................................................. 1988-04
SEALING RINGS
--- K83901 1 Sealing Ring Kit .................................................... A540E ............................................ 1988-93
--- K83901C 1 Sealing Ring Kit .................................................... A541E ............................................ 1994-04
20A 81200T 2 Stator Shaft (Direct Clutch) ..................................... Teflon ............................................ 1988-04
21A 81201T 3 Input Shaft (Forward Clutch) .................................. Teflon ............................................ 1988-04
22E 81202T 1 Intermediate Shaft .................................................. Teflon ............................................ 1988-04
23G 67205F 2 Overdrive Clutch Drum ........................................... Metal ............................................. 1988-04
2013.1.0
13.4-3
 Toyota A540E/H, A541E (FWD 4-Speed)
ILL. PART PER
NO. NUMBER CAR DESCRIPTION YEARS

CLUTCH PLATES

Toyota A540
30A 72306 3 Direct Friction ................................................... 32T, .081” - ....................................... 1988-91
30A 72302 3 Direct Friction .......................................... 40T, .082” - 5.180” O.D. .............................. 1992-04
30A 81304 3 Direct Friction (AWD) .......................................... 40T, .068” ......................................... 1989-91
30A 81304D 3 Direct Friction (AWD) .......................................... 40T, .073” ......................................... 1996-00
31A 72303 2 Direct Steel .......................................................... 6T, .091” .......................................... 1988-91
31A 72303B 1 Direct Steel .......................................................... 6T, .071” .......................................... 1988-91
31A 72303C 1 Direct Steel .......................................................... 6T, .055” .......................................... 1992-04
31A 72303D 2-3 Direct Steel .......................................................... 6T, .079” .......................................... 1992-04
31A 81305 3-4 Direct Steel (AWD) ............................................... 8T, .068” .......................................... 1989-00

32A 81304 4 Forward Friction ................................................. 40T, .068” ......................................... 1988-04

32A 83304 5 Forward Friction ..................................... 40T, .060” - 4.960” O.D. ............................. 1992-04
33A 81305 4 Forward Steel ...................................................... 8T, .068” .......................................... 1988-04
33A 83305 4 Forward Steel ............................................ 8T, .063” - 4.133” I.D. ................................ 1992-04
33A 83305A 1 Forward Steel ............................................ 8T, .055” - 4.133” I.D. ................................ 1992-04
33A 72305 5 Forward Steel ...................................................... 8T, .079” ........................................... 6/97-04

34B 83306 3 2nd Friction (Parallel Lining) .................. 33T, .075” - 5.629” O.D. .............................. 1988-04
34B 83306A 3 2nd Friction (Smooth Lining) .................. 33T, .075” - 5.629” O.D. .............................. 1992-04
34B 83306C 4 2nd Friction .............................................. 36T, .075” - 5.866” O.D. .............................. 1994-04
35B 83307 3 2nd Steel ................................................... 12T, .071” - 4.566” I.D. ............................... 1988-04
35B 83307C 4 2nd Steel (Wide Tooth) ............................. 10T, .071” - 4.881” I.D. ............................... 1994-04
35B 81322A 3 2nd Steel (AWD) ................................................. 12T, .072” ......................................... 1989-00
36C 83321 6-7 1st/Reverse Friction ................................ 33T, .059” - 5.590” O.D. .............................. 1988-04
36C 83321C 6 1st/Reverse Friction ................................ 36T, .059” - 5.787” O.D. .............................. 1994-04
37C 81322 6-7 1st/Reverse Steel ............................................... 12T, .068” ......................................... 1988-04
37C 83322C 6 1st/Reverse Steel ..................................... 10T, .063” - 4.842” I.D. ............................... 1994-04

38F 83308A 3 Overdrive Brake Friction .......................... 24T, .081” - 6.456” O.D. .............................. 1988-04
38F 81308 3 Overdrive Brake Friction ..................................... 24T, .075” ......................................... 1994-04
39F 83309 3 Overdrive Brake Steel ............................... 12T, .098” - 5.629” I.D. ............................... 1988-04
40F 81304D 2 Overdrive Direct Friction ..................................... 40T, .073” ......................................... 1988-04
41F 81305D 2 Overdrive Direct Steel ................................... 20/24Teeth, .071” ....................................... 1988
41F 83311 2 Overdrive Direct Steel ......................... 20/24Teeth, .118” - 4.094” I.D. ........................ 1989-04
41F 83311C 1 Overdrive Direct Steel ............................... 24T, .071” - 4.094” I.D. ............................... 1994-04
41F 83311E 1 Overdrive Direct Steel ............................... 24T, .141” - 4.094” I.D. ............................... 1994-04
--- 83323 11 Differential Lock Friction .......................... 36T, .071” - 4.527” O.D. .............................. 1989-04
--- 83324 11 Differential Lock Steel .............................. 30T, .063” - 3.582” I.D. ............................... 1989-04

BANDS
45A 83714 1 2nd Coast Brake .................................................. A540E/H .......................................... 1988-00
45A 83714C 1 2nd Coast Brake ................................................... A541E ............................................ 1994-04
45A 81714 1 2nd Coast Brake ............................................. A540H - RAV4 ...................................... 1996-00

BUSHINGS
--- K83980 1 Bushing Assortment Kit .................................. A540E / A541E ..................................... 1988-04
--- K83980A 1 Bushing Assortment Kit ........................................ A540H ............................................ 1989-00
50A 67005 1 Front Pump ..................................................................................................................... 1988-04
51A 67002C 1 Stator Support (Front) ..................................................................................................... 1988-04
--- 81001 1 Stator Support (Rear) ...................................... Some Models ...................................... 1988-04
52A 81003 1 Direct Drum ........................................................... A540H ............................................ 1989-00
52A 83003 1 Direct Drum ..................................................... A540E / A541E ..................................... 1988-04
53B 81007 1 Front Ring Gear Hub ............................................. A540H ............................................ 1989-00
53B 83007 1 Front Ring Gear Hub ....................................... A540E / A541E ..................................... 1988-04
54B 81006 2 Sun Gear ............................................................... A540H ............................................ 1989-00
54B 83006 2 Sun Gear ......................................................... A540E / A541E ..................................... 1988-04
55G 81002 1 O/D Sun Gear/Drum (Front) ........................................................................................... 1988-04
56G 81004 1 O/D Sun Gear/Drum (Rear) ........................................................................................... 1988-04
2013.1.0
13.4-4
 Toyota A540E/H, A541E (FWD 4-Speed) - Cont’d.
ILL. PART PER
NO. NUMBER CAR DESCRIPTION YEARS

THRUST WASHERS
--- K83940 1 Thrust Washer Assortment Kit ............................. A540E/H .......................................... 1988-00
--- K83940C 1 Thrust Washer Assortment Kit .............................. A541E ............................................ 1994-04

--- 81400 1 Pump Washer ................................................................................................................ 1988-04

--- 83400C 1 Front Planetary Washer (Rear, 3-Pin) ................... A541E ............................................ 1994-04
--- 83401C 1 Rear Planetary (Front, 3-Pin) ................................ A541E ............................................ 1994-04
--- 83402C 1 Rear Planetary (Rear, 2-I.D. Tabs) ........................ A541E ............................................ 1994-04

SPRAGS
70B 83815 1 Intermediate (B2) Clutch Sprag ........................... A540E/H .......................................... 1988-00
70B 83815C 1 Intermediate (B2) Clutch Sprag ............................ A541E ............................................ 1994-04
70B K83815C 1 Intermediate (B2) Clutch Sprag w/Outer Race ..... A541E ............................................ 1994-04
71B 81814A 1 Rear Planetary Sprag ............................... 20 Elements - A540E/H .............................. 1988-00
71B 83814 1 Rear Planetary Sprag ............................... 30 Elements - A540E/H .............................. 1988-00
71B 83814C 1 Rear Planetary Sprag ................................ 32 Elements - A541E ................................ 1994-04
71B K83814C 1 Rear Planetary Sprag w/Outer Race ......... 32 Elements - A541E ................................ 1994-04
72E 72813 1 Overdrive Sprag ......................................................... All ............................................... 1988-04

TRANSMISSION OIL FILTERS

80E 83600 2 1 Oil Filter ................................................................ A540E/H .......................................... 1988-00
80E 83600C 2 1 Oil Filter ................................................................. A541E ............................................ 1994-04

81E ATK-108 1 Oil Filter Kit ........................................................... A540E/H .......................................... 1988-00

81E ATK-170 1 Oil Filter Kit ............................................................ A541E ............................................ 1994-04
2
Please See Filter Pictures on Page 13.11-1 for Visual Identification.

SHIFT ENHANCEMENTS
--- ST83944 3 1 Valve Body Kit (Superior, Translab Version) ....... A540E/H .......................................... 1988-93
3
Addresses: Harsh Engagements, Soft Shifts, Poor Cooler Flow and O/D Failure.

--- K83889 4 1 Boost Sleeve Kit (Sonnax) .............. Large Ratio, .482” - .583” Spools ...................... 1988-04
4
Addresses high and/or low line pressure.

--- K81989 1 Oversized Pressure Regulator Valve Kit (A540 Only, Use w/K81589 Reamer Kit) ...... 1988-00
--- K83989 1 Oversized Pressure Regulator Valve Kit (A540 w/540Y Stamped on Valve Body) ...... 1988-00
--- K81589 1 Reamer Kit (For K81989 & K83989 Pressure Regulator Valve Kit) ............................ 1988-00

--- 81886 1 Accumulator Control Valve Sleeve .. Usually Worn, Controls Shift Feel ...................... 1988-04

ELECTRICAL COMPONENTS
90E 83871 1 Shift Solenoid Assembly (1 & 2 / A & B) ............... A540E/H .......................................... 1988-00
91E 83870 1 T.C.C. Solenoid (SL / E) ....................................... A540E/H .......................................... 1988-00
--- 83871C 1 Shift Solenoid Assembly (1 & 2 / A & B) ................. A541E ............................................ 1994-04
--- 83873C 1 SLN Solenoid (PWM Accumulator Solenoid) ........ A541E ............................................ 1994-04
--- 83870C 1 T.C.C. (SL / E) Solenoid ........................................ A541E ............................................ 1994-04

MISCELLANEOUS AND HARD PARTS

100D 83880 1 Crush Sleeve ........................................................ A540E/H .......................................... 1988-04
100D 83880C 1 Crush Sleeve ......................................................... A541E ............................................ 1994-04
105D 83891 1 Pinion Shaft Nut ............................................................................................................. 1988-04

150G 70-101 1 Reman Valve Body ......................... A540E w/Three Solenoids, w/Tube ..................... 1988-04
150G 70-102 1 Reman Valve Body ........................ A540E w/Three Solenoids, w/o Tube ................... 1988-04
150G 70-102A 1 Reman Valve Body ................................. Sienna w/Casting A540Y ............................. 1998-00
150G 70-103 1 Reman Valve Body ................................. A540H w/Four Solenoids ............................. 1988-04

2013.1.0
13.4-5