TOYOTA RAV4 1996 Service Repair Manual

Fig. 14: Exploded View Of Transaxle Internal Components
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 27 © 2005 Mitchell Repair Information Company, LLC.

Fig. 15: Checking Operation & Removing 1st & Reverse 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
Helpmelearn
November-03-08 10:28:17 AMPage 28 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Compressing 1st & Reverse Brake Piston Springs
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Differential & Drive Pinion Removal
1. Using INCH-lb. torque wrench, measure and record differential total preload. See Fig. 17 . Remove left
differential bearing retainer. Ensure case or retainer is not damaged if prying is necessary.
2. On A-540E and A-541E transaxles, remove right bearing retainer. On all transaxles, remove carrier cover
bolts in crisscross pattern. Remove cover. Remove apply port gasket at lower portion of case. Remove
differential assembly.
3. From converter side of case, remove drive pinion cap. Using INCH-lb. torque wrench, measure drive
pinion preload. See Fig. 17
. Starting preload should be 4.3-6.9 INCH lbs. (.5-.8 N.m). Subtract drive
pinion preload from total preload.
4. If difference is not 1.1-1.7 INCH lbs. (about .1 N.m), differential side bearing preload may not have been
within specification. Carefully inspect condition of all bearings and replace as needed. See appropriate
component disassembly and reassembly procedure under OVERHAUL.
5. Bend back locking washer securing nut on drive pinion shaft. Secure driven gear and remove nut. Using
appropriate puller, remove driven gear and bearing. Using appropriate 2-jaw puller, remove outer race,
spacer and oil slinger. On A-540E transaxle, remove sensor rotor.
6. On all transaxles, remove snap ring. Turn transaxle case, converter side facing up. Install appropriate bar
into hole in drive pinion. Press out drive pinion shaft. Remove bearing cage from drive pinion. Press off
bearing if replacement is needed.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:17 AMPage 29 © 2005 Mitchell Repair Information Company, LLC.

Fig. 17: Checking Driven Pinion Preload Or Total Preload
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MANUAL SHIFT LINKAGE DISASSEMBLY & REASSEMBLY
Disassembly & Reassembly
1. Remove parking lock pawl bracket. Using hammer and chisel, cut collar on manual valve shaft. Remove
retaining spring. Drive out roll pin on shaft.
2. Slide out shaft from case and remove manual valve lever and parking lock rod. Remove shaft oil seal.
Remove pin, spring and parking lock pawl.
3. To assemble, reverse disassembly procedure. Use NEW collar. Lubricate seal before installing manual
valve lever shaft. Check operation of parking lock pawl.
OIL PUMP DISASSEMBLY & REASSEMBLY
Disassembly
Remove "O" ring and 2 oil seal rings from pump body and stator shaft. Remove clutch drum thrust washer from
stator shaft. Remove bolts attaching oil pump body and stator shaft. Identify top and bottom and keep parts in
order. Separate stator shaft and pump body. Mark gear locations for reassembly reference. See Fig. 18
. Remove
front seal.
Inspection

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 30 © 2005 Mitchell Repair Information Company, LLC.

1. Check body clearance of driven gear. Push gear to one side of body. Measure body clearance. See Fig.
19 . Clearance should be .0028-.0059" (.070-.150 mm). Maximum clearance is .012" (.30 mm). If worn
beyond specification, replace pump body.
2. Check tip clearance of driven gear. Measure between gear teeth and crescent-shaped part of pump body.
See Fig. 19
. Tip clearance should be .0043-.0055" (.110-.140 mm). Maximum tip clearance is .012" (.30
mm). If tip clearance is greater than maximum specification, replace pump body.
3. Using a steel straightedge and feeler gauge, measure side clearance of both gears. See Fig. 19
. Clearance
should be .0008-.0020" (.020-.050 mm). Maximum side clearance is .004" (.10 mm). If worn beyond
specification, replace pump body. Drive and driven gears are available in different thicknesses. See OIL
PUMP DRIVE & DRIVEN GEAR SPECIFICATIONS table.
OIL PUMP DRIVE & DRIVEN GEAR SPECIFICATIONS
4. Measure inside diameter of oil pump body bushing. Maximum inside diameter is 1.503" (38.18 mm). If
inside diameter is greater than maximum specification, replace oil pump body. Measure inside diameter
of stator shaft bushing. Maximum diameter of stator shaft bushing is .849" (21.57 mm). If worn beyond
specification, replace stator shaft.
Reassembly
1. Install NEW oil seal. Seal is properly installed when it is flush with outer edge of pump body. Install
driven gear and drive gear. Ensure identifying marks are facing upward. Install stator shaft on pump
body. Align bolt holes. Install stator shaft-to-oil pump body bolts. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
.
2. Align tab of washer with hollow of pump body. Install thrust washer. Install 2 oil seal rings on oil pump.
DO NOT spread ring ends more than required for installation. Ensure oil seal rings move freely. Turn
drive gear with screwdriver to ensure smooth rotation.
ID MarkThickness - In. (mm)
A-540E & A-541E
A.3717-.3723 (9.440-9.456)
B.3723-.3730 (9.456-9.474)
C.3730-.3736 (9.474-9.490)
A-540H
F.4209-.4212 (10.690-10.699)
G.4213-.4216 (10.700-10.709)
H.4217-.4220 (10.710-10.720)
J.4221-.4224 (10.721-10.730)
K.4225-.4228 (10.731-10.740)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:17 AMPage 31 © 2005 Mitchell Repair Information Company, LLC.

Fig. 18: Exploded View Of Oil Pump
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
Helpmelearn
November-03-08 10:28:17 AMPage 32 © 2005 Mitchell Repair Information Company, LLC.

Fig. 19: Measuring Oil Pump Clearances
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DIRECT CLUTCH DISASSEMBLY & REASSEMBLY

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:17 AMPage 33 © 2005 Mitchell Repair Information Company, LLC.

Disassembly
1. Prior to disassembly, check piston stroke of direct clutch. Measure piston stroke by applying 57-114 psi
(4-8 kg/cm
2 ) of compressed air. See Fig. 20 . Piston stroke should be .036-.053" (.91-1.35 mm) for A-
540E and A-541E transaxles or .044-.058" (1.11-1.47 mm) for A-540H transaxle. If piston stroke is
greater than maximum, inspect each component.
2. Remove snap ring from clutch drum. Remove flange, discs and plates. Note number and location of
components. See Fig. 21
. Compress piston return springs and remove snap ring. Remove spring retainer.
Slide direct clutch onto oil pump. Remove piston by applying low pressure compressed air. See Fig. 20
.
Remove direct clutch from oil pump. Remove "O" ring from clutch piston.
Inspection
Shake piston to ensure direct clutch piston check ball is free. Ensure valve does not leak by applying low
pressure compressed air. Inspect discs, plates and flange. Measure inside diameter of direct clutch bushing.
Maximum inside diameter is 1.900" (48.27 mm) for A-540E and A-541E transaxles or 1.853" (47.07 mm) for
A-540H transaxle. If inside diameter is excessive, replace direct clutch.
Reassembly
1. Install NEW "O" rings on piston. Coat rings with ATF. Press piston in drum with cup side up. Ensure "O"
ring is not damaged. Install piston return springs. Install retainer and snap ring.
2. Install plates, discs and flange. Install flange with flat side facing inward. Install outer snap ring. Ensure
end gap of snap ring is not aligned with cut-outs in direct clutch drum.
3. Install direct clutch on oil pump. Check piston stroke. Using a dial indicator, measure piston stroke by
applying and releasing 57-114 psi (4-8 kg/cm
2 ) of compressed air. See Fig. 20 .
4. Piston stroke should be .036-.053" (.91-1.35 mm) for A-540E and A-541E transaxles or .044-.058" (1.11-
1.47 mm) for A-540H transaxle. If piston stroke is less than specification, replace flange. Flange is
available in thicknesses of .106" (2.70 mm) and .118" (3.00 mm) for A-540E and A-541E transaxles
or .102" (2.60 mm), .110" (2.80 mm) and .118" (3.00 mm) for A-540H transaxle.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:18 AMPage 34 © 2005 Mitchell Repair Information Company, LLC.

Fig. 20: Checking Direct Clutch Piston Stroke
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
Helpmelearn
November-03-08 10:28:18 AMPage 35 © 2005 Mitchell Repair Information Company, LLC.

Fig. 21: Exploded View Of Direct Clutch
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
FORWARD CLUTCH DISASSEMBLY & REASSEMBLY
Disassembly
1. Prior to disassembly, check piston stroke of forward clutch. Using a dial indicator, measure piston stroke
by applying and releasing 57-114 psi (4-8 kg/cm
2 ) of compressed air. See Fig. 22 . Piston stroke should
be .071-.087" (1.79-2.21 mm) for A-540E and A-541E transaxles or .056-.072" (1.41-1.82 mm) for A-
540H transaxle. If piston stroke is greater than maximum, inspect each component.
2. Remove snap ring from clutch drum. See Fig. 23
. Remove flange, discs and plates. Note number and
location of components. Using appropriate compressor, compress springs and remove snap ring. Remove
return sprin
g assembly. Remove retainer and springs. Apply compressed air to oil passage to remove

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:18 AMPage 36 © 2005 Mitchell Repair Information Company, LLC.