TOYOTA RAV4 1996 Service Repair Manual

clutch.
Vehicle Does Not Move In Reverse ("R")
Check 1-2 shift valve, 2-3 shift valve, 2nd coast brake, front planetary gear, rear planetary gear, direct clutch,
OD direct clutch and 1st and reverse brake.
No 1-2 &/Or 2-3 Upshift
Check Throttle Position (TP) sensor circuit, No. 1 and No. 2 shift solenoid circuit, Vehicle Speed Sensor (VSS)
circuit, Electronic Control Transmission Electronic Control Module (ECT ECM), 1-2 shift valve, 2-3 shift
valve, 2nd brake, direct clutch and No. 1 one-way clutch.
No 3-O/D Upshift
Check OD switch and OD OFF indicator switch circuit, OD cancel signal circuit, No. 1 and No. 2 shift solenoid
circuit, VSS, Engine Coolant Temperature (ECT) circuit, ECT ECM, 3-4 shift valve and OD brake.
No O/D-3 Downshift
Check No. 1 and No. 2 shift solenoid valve, VSS circuit, OD cancel signal circuit, ECT ECM and 3-4 shift
valve.
No 3-2 &/Or 2-1 Downshift
Check No. 1 and No. 2 shift solenoid valve, VSS circuit, TP sensor circuit, ECT ECM, 2-3 shift valve, 1-2 shift
valve and 2nd coast brake.
No Torque Converter Lock-Up
Check shift solenoid valve SL circuit, TP sensor circuit, VSS circuit, OD cancel circuit, brakelight circuit, ECT
circuit, ECT ECM, lock-up relay valve and torque converter clutch.
Torque Converter Lock-Up Will Not Release
Check shift solenoid valve SL circuit, TP sensor circuit, brakelight circuit, ECT ECM circuit, lock-up relay
valve and torque converter clutch.
Shift Speeds Too High Or Too Low
Check TP sensor circuit, VSS circuit, shift solenoid valve SL circuit, OD cancel signal circuit, pattern select
switch circuit and ECT ECM.
Harsh Engagement Neutral To Reverse
Check direct clutch accumulator, direct clutch, throttle valve and 1st and reverse brake.
Harsh Engagement Neutral To Drive

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Check forward clutch accumulator, throttle valve and forward clutch.
No Engine Braking In Low
Check low coast modulator valve and 1st and reverse brake.
No Engine Braking In 2nd
Check 2nd coast modulator valve and 2nd coast brake.
CLUTCH & BRAKE APPLICATION
Selector Lever
Position
Elements In Use
"D" (Drive)
1st GearForward Clutch, OD Direct Clutch, OD One-Way Clutch & No. 2 One-Way
Clutch
2nd GearForward Clutch, OD Direct Clutch, OD One-Way Clutch, No. 1 One-Way
Clutch & 2nd Brake
3rd GearForward Clutch, Direct Clutch, OD Direct Clutch, OD One-Way Clutch & 2nd
Brake
OverdriveDirect Clutch, Forward Clutch, OD Brake & 2nd Brake
"2" (Second)
1st GearForward Clutch, OD One-Way Clutch, OD Direct Clutch & No. 2 One-Way
Clutch
2nd GearForward Clutch, OD Direct Clutch, OD One-Way Clutch, 2nd Brake, 2nd Coast
Brake & No. 1 One-Way Clutch
3rd Gear (1)Forward Clutch, Direct Clutch, Direct Clutch, OD One-Way Clutch & 2nd
Brake
"L" (Low)
1st GearForward Clutch, OD Direct Clutch, OD One-Way Clutch, & 1st & Reverse
Brake & No. 2 One-Way Clutch
2nd Gear (2)Forward Clutch, OD Direct Clutch, OD One-Way Clutch, No. 1 One-Way
Clutch, 2nd Brake & 2nd Coast Brake
"R" (Reverse)Direct Clutch, OD Direct Clutch & 1st & Reverse Brake
"N" (Neutral)OD Direct Clutch
"P" (Park)OD Direct Clutch
(1)Downshift only in 3rd gear for "2" position.
(2)Downshift only in 2nd gear for "L" position. Upshift does not occur.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 4: Identifying Transaxle Component Locations
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TESTING
PRELIMINARY CHECK
Ensure a thorough explanation of when and how transaxle malfunction occurs is received from customer. Check
fluid level and condition. Retrieve Diagnostic Trouble Codes (DTC's). See appropriate ELECTRONIC
CONTROLS article. Proceed as necessary. If no codes are present, proceed with symptom diagnosis. See
TROUBLE SHOOTING
. Check throttle cable adjustment. See ON-VEHICLE SERVICE . Perform STALL
SPEED, TIME LAG and HYDRAULIC PRESSURE TESTS as needed. After repairs are completed, perform
ROAD TEST to confirm repairs.
TIME LAG TEST
CAUTION: Perform this test at normal operating fluid temperature of 122-176°F (50-
80°C). Allow a one minute interval between tests. Record 3 measurements
and average results.

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1. If shift lever is actuated with engine idling, a time lag will be noted before shock can be felt. This test is
used for checking condition of OD direct clutch, forward clutch, direct clutch, and 1st and reverse brake.
2. Apply parking brake. Start engine. On RAV4, ensure idle speed is 700-800 RPM. On all other models,
ensure idle speed is 650-750 RPM. Shift transaxle from "N" into "D" range. Use a stop watch to measure
elapsed time between shifting of lever until shock is felt. Standard time lag is less than 1.2 seconds.
3. Repeat procedure outlined in step 2) to measure time lag for "N" to "R". Standard lag time is less than 1.5
seconds.
4. If "N" to "D" time lag is longer than specification, line pressure is too low, forward clutch may be worn,
or OD one-way clutch is not operating properly.
5. If "N" to "R" time lag is longer than specified, direct clutch may be worn, 1st and reverse brake may be
worn, line pressure is too low or OD one-way clutch is not operating properly.
ROAD TEST
"D" Range Test In NORM & PWR Pattern Ranges
1. Shift into "D" range. Hold accelerator pedal constant at full throttle. Place shift mode button in NORM or
PWR position. Check 1-2, 2-3, and 3-OD lock-up and upshift points. See appropriate table under SHIFT
SPEED SPECIFICATIONS .
zIf no 1-2 upshift occurs, check 1-2 shift valve or solenoid.
zIf no 2-3 upshift occurs, check 2-3 shift valve or solenoid.
zIf no 3-OD upshift occurs, check 3-OD shift valve.
zIf all shift points are incorrect, check throttle valve, 1-2 shift valve, 2-3 shift valve and 3-OD shift
valve.
zIf all lock-up points are incorrect, check lock-up relay valve or shift solenoid valve SL.
2. Use procedure outlined in step 1) to check for shock and slip between 1-2, 2-3, and 3-OD upshifts. If
shock is harsh, line pressure may be too high. Check accumulator or check ball.
3. Run vehicle in "D" range lock-up or overdrive gear. Check for abnormal noise and vibration.
4. While running in "D" range, confirm correct kickdown vehicle speed limits for 2-1, 3-2, OD-3 shift
points. Check for abnormal shock and slip at kickdown.
5. Check loc
k-up function. Drive vehicle in OD gear of "D" range with lock-up on. Hold vehicle speed NOTE: Perform test at normal operating fluid temperature of 122-176°F (50-80°C).
NOTE: There is no overdrive upshift when coolant temperature is below 140°F
(60°C). There is no lock-up when vehicle speed is 6 MPH less than the set
cruise control speed.
NOTE: Check for cause of abnormal noise and vibration must be made with
extreme care as problem could be due to an unbalanced drive shaft,
differential, tire, torque converter, etc.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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steady at 43 MPH for 1997 Avalon, 47 MPH for RAV4 and 37 MPH for all other models. Lightly depress
accelerator pedal. Ensure engine RPM does not change abruptly. Large increase in engine RPM indicates
lock-up function is faulty.
"2" Range Test
1. Shift into "2" range and fully depress accelerator pedal to full throttle. Ensure 1-2 upshift takes place and
shift point conforms to specifications. See appropriate table under SHIFT SPEED SPECIFICATIONS
.
2. While driving in "2" range, 2nd gear, release accelerator pedal and check engine braking effect. If there is
no engine braking effect, 2nd coast brake is faulty. Check for abnormal noise and shock at acceleration
and deceleration.
"L" Range Test
While running in "L" range, ensure there is no upshift to 2nd gear. While running in "L" range, release
accelerator pedal. If there is no engine braking effect, 1st and reverse brake is faulty. Check for abnormal noise
at acceleration and deceleration.
"R" Range Test
Shift into "R" range. Accelerate vehicle from a stop at full throttle. Ensure slipping does not occur.
"P" Range Test
Stop vehicle on 5 degree or more gradient. Shift transaxle into "P" range. Release parking brake. Ensure parking
pawl holds vehicle.
SHIFT SPEED SPECIFICATIONS
AVALON A-541E SHIFT SPEED SPECIFICATIONS
Application (1)MPH
"D" Range (NORM or PWR)
1st-2nd41-44
2nd-3rd76-81
3rd-OD117-123
3rd-OD (2)24-27
OD-3rd (2)12-15
OD-3rd113-118
3rd-2nd70-75
2nd-1st34-37
"2" Range (NORM or PWR)
1st-2nd41-44
3rd-2nd83-88
2nd-1st34-37

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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AVALON A-541E LOCK-UP SPEEDS
CAMRY & CAMRY SOLARA (V6) A-541E SHIFT SPEED SPECIFICATIONS
"L" Range (NORM or PWR)
3rd-2nd72-77
2nd-1st37-39
(1)Wide open throttle.
(2)Fully closed throttle.
Application (1)MPH
"D" Range (NORM or PWR) (2)
1997
Lock-Up ON In 3rd (3)40-43
Lock-Up OFF In 3rd (3)36-39
Lock-Up ON In OD40-43
Lock-Up OFF In OD36-39
1998
Lock-Up ON In 3rd (3)37-40
Lock-Up OFF In 3rd (3)33-36
Lock-Up ON In OD37-40
Lock-Up OFF In OD33-36
(1)Throttle valve opening 5 percent.
(2)There is no lock-up in "L" or "2" ranges.
(3)With OD switch off.
Application (1)MPH
"D" Range
1st-2nd37-41
2nd-3rd70-75
3rd-OD108-113
3rd-OD (2)22-24
OD-3rd (2)12-15
OD-3rd104-109
3rd-2nd65-70
2nd-1st31-34
"2" Range
1st-2nd37-41
3rd-2nd76-81

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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CAMRY & CAMRY SOLARA (V6) A-541E LOCK-UP SPEEDS
LEXUS ES300 A-541E SHIFT SPEED SPECIFICATIONS
2nd-1st31-34
"L" Range
3rd-2nd66-71
2nd-1st34-37
(1)Wide open throttle.
(2)Fully closed throttle.
Application (1)MPH
"D" Range (2)
Lock-Up ON In 3rd (3)37-40
Lock-Up OFF In 3rd (3)33-35
Lock-Up ON In OD37-40
Lock-Up OFF In OD33-35
(1)Throttle valve opening 5 percent.
(2)There is no lock-up in "L" or "2" ranges.
(3)With OD switch off.
Application (1)MPH
"D" Range
1st-2nd37-41
2nd-3rd70-75
3rd-OD108-113
3rd-OD (2)22-24
OD-3rd (2)12-15
OD-3rd104-109
3rd-2nd65-70
2nd-1st31-34
"2" Range
1st-2nd37-41
3rd-2nd76-81
2nd-1st31-34
"L" Range
3rd-2nd66-71
2nd-1st34-37
(1)Wide open throttle.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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LEXUS ES300 A-541E LOCK-UP SPEEDS
RAV4 A-540H SHIFT SPEED SPECIFICATIONS
RAV4 A-540H LOCK-UP SPEEDS
(2)Fully closed throttle.
Application (1)MPH
"D" Range (2)
Lock-Up ON In 3rd (3)37-40
Lock-Up OFF In 3rd (3)33-35
Lock-Up ON In OD37-40
Lock-Up OFF In OD33-35
(1)Throttle valve opening 5 percent.
(2)There is no lock-up in "L" or "2" ranges.
(3)With OD switch off.
Application (1)MPH
"D" Range (NORM or PWR)
1st-2nd35-39
2nd-3rd64-70
3rd-OD101-108
3rd-OD (2)19-22
OD-3rd (2)10-12
OD-3rd90-96
3rd-2nd58-64
2nd-1st27-30
"2" Range (NORM or PWR)
1st-2nd35-39
2nd-1st27-30
"L" Range (NORM or PWR)
3rd-2nd62-68
2nd-1st27-30
(1)Wide open throttle.
(2)Fully closed throttle.
Application (1)MPH
"D" Range (2)
NORM

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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SIENNA A-540E SHIFT SPEED SPECIFICATIONS
SIENNA A-540E LOCK-UP SPEEDS
Lock-Up ON In 3rd (3)39-43
Lock-Up OFF In 3rd (3)35-38
Lock-Up ON In OD37-40
Lock-Up OFF In OD30-33
PWR
Lock-Up ON In 3rd (3)48-51
Lock-Up OFF In 3rd (3)37-40
Lock-Up ON In OD41-44
Lock-Up OFF In OD34-37
(1)Throttle valve opening 5 percent.
(2)There is no lock-up in "L" or "2" ranges.
(3)With OD switch off.
Application (1)MPH
"D" Range
1st-2nd37-41
2nd-3rd68-76
3rd-OD106-115
3rd-OD (2)23-27
OD-3rd (2)13-16
OD-3rd103-110
3rd-2nd67-71
2nd-1st31-34
"2" Range
1st-2nd37-41
3rd-2nd75-82
2nd-1st31-34
"L" Range
3rd-2nd65-71
2nd-1st33-37
(1)Wide open throttle.
(2)Fully closed throttle.
Application (1)MPH
"D" Range (2)

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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STALL SPEED TEST
1. Object of test is to check overall performance of transaxle and engine by measuring maximum stall
speeds in "D" and "R" ranges.
2. Block front and rear wheels. Connect scan tool to DLC3, located under instrument panel. Apply parking
and service brakes. Start engine. Position transmission in "D" range. Fully depress accelerator pedal.
Immediately note highest engine RPM. DO NOT perform test longer than 5 seconds. Repeat test in "R"
range. See STALL SPEED SPECIFICATIONS
table.
STALL SPEED SPECIFICATIONS
3. If stall speed is same for both ranges, but lower than specified RPM, engine output may be insufficient or
stator one-way clutch is not operating properly.
4. If stall speed in "D" range is higher than specifications, forward clutch may be slipping, No. 2 one-way
clutch and OD one-way clutch are not operating properly, or line pressure is too low.
5. If stall speed in "R" range is higher than specifications, direct clutch is slipping, 1st and reverse brake is
slipping, OD direct clutch is slipping or line pressure is too low.
6. If stall speed in "R" and "D" ranges is higher than specifications, line pressure is too low, fluid level is
incorrect or OD one-wa
y clutch is not operating properly.
Lock-Up ON In 3rd (3)36-40
Lock-Up OFF In 3rd (3)32-36
Lock-Up ON In OD36-40
Lock-Up OFF In OD32-36
(1)Throttle valve opening 5 percent.
(2)There is no lock-up in "L" or "2" ranges.
(3)With OD switch off.
CAUTION: Perform test at normal operating fluid temperature of 122-176°F (50-80°C).
DO NOT maintain stall speed RPM for more than 5 seconds. Allow vehicle
to idle in Neutral or Park for at least 5 minutes before performing next test.
ApplicationsRPM
A-540E2300-2750
A-540H2250-2550
A-541E
1998-99 Avalon2250-2550
Except 1998-99 Avalon2450-2750
NOTE: If stall speed RPM is more than 600 RPM below specified value, torque
converter may be faulty.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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November-03-08 10:28:17 AMPage 16 © 2005 Mitchell Repair Information Company, LLC.