A540E Transmission Master Rebuild Kit Toyota Camry

This is a master-level overhaul kit for the Toyota A540E and A540H four-speed automatic, the transaxle used behind the 2.0L, 2.2L and 3.0L engines in the Camry, the Sienna, and the Lexus ES250 and ES300. It is the full package rather than a seal-only kit: 23 friction plates, 22 steel plates, the complete gasket and seal set, the rubber lip seals, the sealing rings, and the cushion rubber that goes back into the drums during assembly.

Fitment covers 1988-1991 Camry 2.0L and 2.5L, 1992-1993 Camry 2.2L and 3.0L, 1990-1991 Lexus ES250 2.5L, 1992-1993 Lexus ES300 3.0L, and 1998-2000 Sienna 3.0L. Cross-reference part numbers are B065820E, W065880E and W065881E. The A540H is the all-wheel-drive version of the same unit and uses the same clutch and seal package.

The A540E fails the way most high-mileage Toyota four-speeds fail: burnt frictions in the direct and forward clutch packs, hardened lip seals in the pistons, and a flare or a slip on the 2-3 shift that gets worse as the fluid heats up. Delayed engagement into drive and a shudder in lockup are the other two you will see on the lift. None of that is fixed by a fluid change once the friction material is on the pan magnet.

On the bench: strip the unit down, clean and inspect the drums for step wear and heat discoloration, and check the steels for cone-shaping before you reuse anything. Soak the new frictions in ATF for at least 20 minutes before assembly. Replace every lip seal and sealing ring on the pistons and shafts, air-check each pack through its feed port once the drum is assembled, then set clutch clearance with the selective snap ring before the unit goes back together.