TOYOTA RAV4 1996 Service Repair Manual

HYDRAULIC PRESSURE TEST
Line Pressure Test
1. Ensure transmission fluid is at operating temperature. Raise and support vehicle. Remove transaxle case
test plug and install pressure gauge. See Fig. 5
. Lower vehicle and block all wheels.
2. Fully apply parking brake. Start engine. Apply brakes. Shift into "D" range. On A-540H transaxle, apply
battery voltage between ground and terminal No. 1 of shift solenoid valve ST connector. See Fig. 6
. On
all transaxles, measure line pressure at idle. Accelerate to full throttle. Measure line pressure at stall
speed. See appropriate LINE PRESSURE SPECIFICATIONS table.
3. On all models, repeat test in "R" range. DO NOT ground shift solenoid valve ST in "R" range.
4. If pressures exceed specifications in all ranges, regulator valve or throttle valve is faulty or throttle cable
is out of adjustment.
5. If pressures in all ranges are lower than specifications, oil pump, regulator valve, throttle valve or OD
direct clutch is faulty or throttle cable is out of adjustment.
6. If pressure is lower than specifications in "D" range only, forward clutch is faulty or "D" range circuit has
a fluid leak.
7. If pressure is lower than specifications in "R" range only, direct clutch is faulty, 1st and reverse brake is
faulty or "R" range circuit has a fluid leak.
LINE PRESSURE SPECIFICATIONS (A-540E)
LINE PRESSURE SPECIFICATIONS (A-540H) 1997
(1)
CAUTION: Hydraulic pressure test should be performed with transmission fluid
temperature of 122-176°F (50-80°C).
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed51-60 (3.6-4.2)
Stall Speed127-148 (8.9-10.4)
"R" Position
Idle Speed93-108 (6.5-7.6)
Stall Speed230-268 (16.1-18.8)
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed
With Solenoid Valve ST On76-102 (5.4-7.2)
With Solenoid Valve ST Off53-61 (3.7-4.3)
Stall Speed
With Solenoid Valve ST On192-225 (13.5-15.8)
With Solenoid Valve ST Off106-125 (7.5-8.8)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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LINE PRESSURE SPECIFICATIONS (A-540H) 1998-99(1)

LINE PRESSURE SPECIFICATIONS (A-541E)
"R" Position
Idle Speed76-102 (5.4-7.2)
Stall Speed192-225 (13.5-15.8)
(1)See Fig. 6 for shift solenoid valve ST activation location.
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed
With Solenoid Valve ST On76-102 (5.4-7.2)
With Solenoid Valve ST Off53-61 (3.7-4.3)
Stall Speed
With Solenoid Valve ST On165-179 (11.6-12.6)
With Solenoid Valve ST Off249-269 (17.5-18.9)
"R" Position
Idle Speed76-102 (5.4-7.2)
Stall Speed192-225 (13.5-15.8)
(1)See Fig. 6 for shift solenoid valve ST activation location.
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed58-66 (4.1-4.7)
Stall Speed165-179 (11.6-12.6)
"R" Position
Idle Speed117-128 (8.2-9.0)
Stall Speed249-269 (17.5-18.9)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 5: Checking Hydraulic Pressure
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 6: Activating Shift Solenoid Valve ST

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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TORQUE CONVERTER
ONE-WAY CLUTCH TEST
1. Insert a turning tool into inner race of one-way clutch. Install Tester (09350-32014) so that it fits in notch
of converter hub and other race of one-way clutch.
2. With torque converter in normal operating position, clutch should lock when turned counterclockwise and
should rotate freely and smoothly when turned clockwise. See Fig. 7
. If one-way clutch fails test in either
direction, clean converter. Retest clutch. If clutch fails test, replace converter.
Fig. 7: Testing Torque Converter One
-Way Clutch
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CONVERTER SLEEVE RUNOUT TEST
1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on
converter sleeve. See Fig. 8
. Rotate converter. If runout exceeds .012" (.30 mm), ensure converter is
properly mounted to drive plate.
2. If converter is properl
y mounted and runout exceeds specifications, replace torque converter. Mark NOTE: Torque converter is a sealed unit and must be serviced as complete assembly.
Perform following tests to check converter condition. Torque converter and oil
cooler lines must be thoroughly cleaned and flushed if transaxle fluid is
contaminated.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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position of converter to ensure correct installation. Remove converter from drive plate.
DRIVE PLATE (FLYWHEEL) RUNOUT TEST
Measure drive plate runout. See Fig. 9
. If runout exceeds .008" (.20 mm), or if ring gear is damaged, replace
drive plate. If installing a NEW drive plate, note position of spacers. Tighten bolts to 61 ft. lbs. (83 N.m).
Fig. 8: Measuring Torque Converter Sleeve Runout

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 9: Checking Drive Plate Runout
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
For transaxle removal procedure, see appropriate AUTOMATIC TRANSMISSION REMOVAL article in
TRANSMISSION SERVICING.
OVERHAUL
TRANSAXLE DISASSEMBLY
1. On A-540H, remove breather hose from drive pinion bearing cage. Remove bolts and nuts on transfer
case assembly. Remove transfer case assembly from transaxle. Remove apply gasket. Using
Remover/Installer (09520-32012), remove differential side gear intermediate shaft. See Fig. 63
.
2. On all transaxles, remove cooler pipe unions and/or elbows. Remove oil cooler pipes (if applicable).
Remove dipstick and filler tube. Remove manual shift lever. Pry back locking tab on manual shaft
NOTE: RAV4 is equipped with a transfer case. For transfer case overhaul procedures,
see TOYOTA A-540H transfer case article in AXLE SHAFTS & TRANSFER
CASES.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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washer. Remove nut and washer. Remove Park/Neutral Position (PNP) switch.
3. Remove throttle cable retaining bolt. Remove solenoid harness connector retaining bolt (if applicable).
Remove vehicle speed sensor mounted in differential cover. Remove sensor adapter. Remove direct
clutch speed (T/M revolution) sensor mounted to upper case cover (if equipped). Remove upper case
cover. Remove transaxle oil pan. Examine any contamination in pan to aid in diagnosis.
4. Remove oil stainer (filter) and oil pipe hold-down bracket. Remove manual valve body including detent
spring. Gently remove all oil pipes by prying up on end of pipe with screwdriver.
5. Disconnect solenoid harness connectors. Remove connector clamp and apply pipe retainer. Remove 1st
and reverse apply pipe. Remove valve body bolts. Remove wiring harness clamp. Disconnect throttle
cable from cam and remove valve body.
6. Remove throttle cable and solenoid wiring harness. Remove 2nd brake apply gasket. Loosen accumulator
cover bolts in crisscross pattern. Remove cover and gasket. Remove forward clutch accumulator. See Fi
g.
10 .
7. Remove remaining accumulators by applying 14 psi (1kg/cm
2 ) of air pressure to apply hole. See Fig.
11 . Cover accumulator bores with a rag when applying air.
8. Mark 2nd coast brake servo apply piston rod where it meets case. Apply 57-114 psi (4-8 kg/cm
2 ) of air
pressure to apply hole and measure piston rod travel (stroke). See Fig. 12
. Piston rod travel should
be .079-.138" (2.0-3.5 mm). If rod travel is not within specification, further inspect band during
disassembly.
9. Remove 2nd coast brake piston cover snap ring. Apply air to oil hole and remove cover and piston
assembly. See Fig. 12
. Remove oil pump bolts. Using appropriate puller, remove oil pump.
10. Remove direct clutch and forward clutch. Separate components and remove thrust washer. Remove thrust
bearings from front and rear of forward clutch. Push out 2nd coast brake band anchor pin. Remove band
and inspect.
11. Remove front planetary ring gear. Remove front planetary gear with thrust bearings on either side.
Remove thrust bearings. Remove sun gear shell with thrust washer.
12. Apply compressed air to 2nd brake piston port and check operation of 2nd brake. See Fig. 13
. Remove
2nd coast brake band guide. DO NOT separate band guide and bolt. Remove snap ring securing 2nd
brake drum. Remove drum.
13. Remove 2nd brake piston return spring. Remove No. 1 one-way clutch. Remove 2nd brake clutch discs,
plates and flange. Note number and location of components. Remove snap ring securing No. 2 one-way
clutch and rear planetary gear. See Fig. 14
. Remove components.
14. Remove thrust washer from rear planetary gear. Remove rear planetary ring gear with thrust bearing.
Apply air into appropriate passage to check 1st and reverse brake operation. See Fig. 15
.
15. Using feeler gauge, check pack clearance of 1st and reverse brake assembly. Clearance should be .033-
.081" (.85-2.05 mm) for A-540E transaxle, .041-.085" (1.04-2.16 mm) for A-540H transaxle, or .076-
.106" (1.92-2.68 mm) for A-541E transaxle. Remove snap ring securing 1st and reverse brake. Remove
1st and reverse brake discs, plates and flange. Note number and location of components.
16. From back of transaxle, remove 13 bolts securing overdrive unit. Using soft-faced hammer, tap around
outside of case until overdrive unit loosens and can be removed.
17. Remove overdrive (OD) planetary gear from transaxle case. Remove OD brake drum. See Fig. 14
.
Remove gaskets for OD clutch apply and OD brake apply ports.
18. Usin
g appropriate compressor, compress 1st and reverse piston. See Fig. 16 . Remove snap ring. Apply

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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compressed air and remove piston. See Fig. 15. Remove inner snap ring.
Fig. 10: Exploded View Of Accumulator Piston Assemblies

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.NOTE: If manual shift linkage is damaged or needs to be disassembled, see MANUAL
SHIFT LINKAGE under COMPONENT DISASSEMBLY & REASSEMBLY.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 11: Removing Accumulator Pistons & Springs
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 12: Checking Operation & Removing 2nd Coast Brake

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 13: Checking Operation & Removing 2nd Brake

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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 26 © 2005 Mitchell Repair Information Company, LLC.