TOYOTA RAV4 1996 Service Repair Manual

1. Remove No. 1 and No. 2 solenoids. See Fig. 32 . DO NOT use a screwdriver to pry up solenoid(s).
Remove "O" ring(s) from solenoid(s). Remove shift solenoid valve SL. Remove shift solenoid valve ST
with check valve sleeve. Remove shift solenoid valve ST from check valve sleeve.
2. Remove key, 2 check valves and check ball from check valve sleeve. Remove OD brake accumulator
assembly. Applying compressed air to accumulator cylinder hole, remove piston and spring. Remove 2
"O" rings from piston.
3. Remove bolts from upper valve body and cover. Note bolt length and location for reassembly reference.
Remove upper valve body cover, oil strainer, gaskets and plate. Remove lock-up relay valve sleeve
stopper. Turn assembly over.
4. Remove bolts from lower valve body and cover. Carefully remove lower valve body cover gaskets and
plate. Note location of check balls, retainers, keys and pins in valve body.
5. Remove 2 check balls from lower valve body. Remove 1 bolt from lower valve body. Remove 3 bolts
from upper valve body. Hold No. 1 plate to upper valve body. Lift off upper valve body and plate as a
unit. DO NOT lose steel balls, retainers and pins in valve body.
Fig. 32: Exploded View Of Valve Body Assembly (A
-540H)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (A-541E)
1. Remove No. 1 and No. 2 solenoids with retainers. Remove No. 3 solenoid. Remove lock plate. Remove
OD brake accumulator assembl
y. Apply compressed air to vent hole on side of accumulator cylinder to

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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remove piston. Remove No. 4 solenoid.
2. Remove lower valve body cover No. 1. See Fig. 33
. Remove separator plate and gaskets. Remove oil
strainer, check valve and spring. Remove pressure relief valve (plate, spring and check ball).
3. Remove lower valve body cover No. 2. Remove 2 check balls, oil strainer and vibrating stopper. Turn
over No. 2 cover. Remove 2 screws and lift off separator plate and gaskets. Remove 3 check balls. See
Fig. 34
.
4. Remove bolts securing upper valve body. Lift off upper valve body and No. 1 separator plate as a single
unit. Turn upper valve body over without allowing check balls to fall out. Remove separator plate.
Remove check ball and vibrating stopper. Remove check balls and oil stainers from lower valve body.
Fig. 33: Exploded View Of Valve Body Assembly (A
-541E)
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. 34: Identifying Lower Valve Body Cover No. 2 Check Ball Locations (A-541E)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly (Upper Valve Body A-540E, A-540H & A-541E)
1. When disassembling upper valve body, maintain parts in order for reassembly reference. Ensure each
valve is kept with corresponding spring. Inspect valve springs for damage, squareness, rust and collapsed
coils.
2. Measure upper valve body valve spring free height. Replace any spring if specification is exceeded. See
appropriate UPPER VALVE BODY VALVE SPRING SPECIFICATIONS
table. Clean all
components with solvent and lubricate with ATF. For parts identification, see Fig. 35
and Fig. 36.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 35: Exploded View Of A-540E & A-540H Upper Valve Body (Viewed From Both Ends)
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. 36: Exploded View Of A-541E Upper Valve Body
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 37: Exploded View Of A
-541E Lower Valve Body
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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UPPER VALVE BODY VALVE SPRING SPECIFICATIONS
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540E)
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540H)
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-541E)
Disassembly & Reassembly (Lower Valve Body A-540E, A-540H & A-541E)
1. When disassembling lower valve body, maintain parts in order for reassembly reference. Ensure each
valve is kept with corresponding spring. Inspect valve springs for damage, squareness, rust and collapsed
coils.
2. Measure lower valve bod
y valve spring free height. Replace any spring if specification is exceeded. See
ApplicationColorFree Height - In. (mm)
2nd Coast Modulator ValveBrown1.083 (27.50)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Downshift PlugYellow1.012 (25.70)
Throttle ValvePurple1.209 (30.70)
Throttle Modulator ValveOrange.854 (21.70)
Cut-Back ValveRed.858 (21.80)
No. 1 Accumulator Control ValveYellow1.106 (28.10)
Lock-Up Relay ValveGreen1.047 (26.60)
ApplicationColorFree Height - In. (mm)
2nd Coast Modulator ValveLight Blue1.126 (28.60)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Downshift PlugYellow1.173 (29.80)
Throttle ValvePurple1.209 (30.70)
Throttle Modulator ValveOrange.854 (21.70)
Cut-Back ValveRed.858 (21.80)
No. 1 Accumulator Control ValveBlue.992 (25.20)
Lock-Up Relay ValveGreen1.047 (26.60)
ApplicationColorFree Height - In. (mm)
Lock-Up Relay ValveYellow1.055 (26.80)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Throttle ValveGreen1.240 (31.50)
Downshift PlugNone.591 (15.00)
Low Coast Modulator ValvePurple.795 (20.20)
NOTE: On A-540H transaxle, line pressure changes according to part of plunger sleeve
which comes into contact with retainer. When reassembling lower valve body,
align retainer in same position.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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appropriate LOWER VALVE BODY VALVE SPRING SPECIFICATIONS table.
LOWER VALVE BODY VALVE SPRING SPECIFICATIONS
LOWER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540E)
LOWER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540H)
LOWER VALVE BODY VALVE SPRING SPECIFICATIONS (A-541E)
ApplicationColorFree Height - In. (mm)
Pressure Relief ValveNone.441 (11.20)
Check ValveNone.783 (19.90)
Secondary Regulator ValvePurple1.516 (38.50)
No. 2 Accumulator ValveGray.906 (23.00)
2nd Lock ValveOrange.815 (20.70)
3-4 Shift ValveLight Green1.150 (29.20)
Low Coast Modulator ValvePurple.795 (20.20)
1-2 Shift ValveNone1.319 (33.50)
2-3 Shift ValveNone1.102 (28.00)
Primary Regulator ValveNone2.528 (64.20)
ApplicationColorFree Height - In. (mm)
Pressure Relief ValveNone.441 (11.20)
Check ValveNone.783 (19.90)
Secondary Regulator ValvePurple1.516 (38.50)
No. 2 Accumulator ValveGray.906 (23.00)
2nd Lock ValveOrange.815 (20.70)
3-4 Shift ValveLight Green1.150 (29.20)
Low Coast Modulator ValvePurple.795 (20.20)
1-2 Shift ValveLight Green1.150 (29.20)
2-3 Shift ValveNone1.102 (28.00)
Primary Regulator ValveNone2.528 (64.20)
ApplicationColorFree Height - In. (mm)
Accumulator Control ValveRed.988 (25.10)
2-3 Shift ValveNone1.102 (28.00)
1-2 Shift ValveLight Green1.150 (29.20)
Reverse Control ValveWhite/Purple1.50 (38.1)
Cut-Back ValveNone.858 (21.80)
Primary Regulator ValveNone1.441 (36.60)
3-4 Shift ValveNone1.102 (28.0)
2nd Lock ValveNone.815 (20.70)
2nd Coast Modulator ValveWhite1.268 (32.20)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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November-03-08 10:28:18 AMPage 53 © 2005 Mitchell Repair Information Company, LLC.

Fig. 38: Exploded View Of A-540H Lower Valve Body (Viewed From Both Ends)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly (Valve Body Assembly A-540E)
1. Position NEW No. 1 gasket, No. 1 separator plate and NEW No. 2 gasket on upper valve body. For
gasket identification, see Fig. 39
. Ensure check balls are correctly installed in lower valve body (bottom).
See Fig. 41
. Place upper valve body with No. 1 plate and gaskets on lower valve body.
2. Hold upper valve bod
y, No. 1 plate and gaskets so they do not separate. Align each bolt hole in valve
Solenoid Modulator ValvePurple/Pink1.189 (30.20)
Secondary Regulator ValveNone1.846 (46.90)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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bodies with gaskets and plate. Note length and location of bolts. Install and finger tighten 3 bolts in upper
valve body to secure lower valve body. See Fig. 42
.
3. Install lock-up relay valve sleeve stopper. Install upper valve body cover gaskets, plate and throttle
modulator oil strainer. Install upper valve body cover, and finger tighten 11 bolts in valve body cover.
See Fig. 42
. Install and finger tighten bolts in lower valve body.
4. Install check balls into lower valve body (top). See Fig. 40
. Install NEW lower valve body cover gaskets
and No. 2 plate. Install lower valve body cover and finger tighten 12 bolts in valve body cover. Tighten
bolts to specification. See TORQUE SPECIFICATIONS
.
5. Coat NEW "O" rings with ATF. Install "O" rings on piston. Insert spring and piston into cylinder. Place
check ball on No. 1 gasket. Install accumulator. Install and tighten 3 bolts. Install lock-up solenoid. Install
No. 1 and No. 2 shift solenoids.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 39: Identifying A-540E Valve Body Gaskets
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 56 © 2005 Mitchell Repair Information Company, LLC.