TOYOTA RAV4 1996 Service Repair Manual

Fig. 58: Checking Differential End Play (A-540H)
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. 59: Checking Operation Of Differential Clutch Pistons (A-540H)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Remove hydraulic multi-plate clutch discs and plates. Remove snap ring. Remove flange, discs and
plates. Note number and location of components. Using Spring Compressor (09350-32014), compress
return spring. Remove snap ring. Apply compressed air to right case hole. Remove No. 1 piston. Remove
"O" ring from No. 1 piston. Using small screwdriver, remove reaction sleeve and No. 2 piston. Remove 3
"O" rings from reaction sleeve and No. 2 piston.
7. Using Bearing Remover and Attachment (09950-00020, 09950-00030), remove ring gear mounting left
case bearing. Using A/T Tool Set (09350-32014) and arbor press, install ring gear mounting left case
bearing.
8. Usin
g a chisel and hammer, cut out ring gear mounting right case bearing cage. DO NOT damage right

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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case. Using A/T Tool Set (09350-32014) and arbor press, remove bearing inner race. Using Bearing
Replacer (09316-60010) and arbor press, install NEW ring gear mounting right case bearing.
9. Use hammer and screwdriver to remove oil seal from ring gear mounting left case. Remove oil baffle
from left bearing retainer. Use hammer and brass bar to drive out outer race and adjusting shim from left
bearing retainer. Place adjusting shim into left bearing retainer. Use either original shim or shim with
thickness of .0945" (2.400 mm). Use A/T Tool Set (09350-32014) and arbor press to install outer race
and shim. Install oil baffle and oil seal after adjusting differential side bearing preload. See
TRANSAXLE REASSEMBLY
.
Reassembly
1. Coat 4 "O" rings with ATF. Install "O" rings on reaction sleeve and pistons. Install No. 1 piston, No. 2
piston and reaction sleeve to ring gear mounting right case.
2. Place return spring on piston. Install A/T Tool Set (09350-32014) on piston return spring retainer.
Compress spring with arbor press. Install snap ring.
3. Install plates and discs, starting with plate, alternating with disc and ending with disc. Install flange with
flat end facing downward. Install snap ring. Check operation of clutch pistons. Plug one hole with your
hand. Apply compressed air into other hole. Ensure pistons move. Install No. 1 thrust washer.
4. Install following parts into front differential left case: side gear thrust washer, side gear, 4 differential
pinion gears, 4 pinion gear thrust washers and differential spider. Use a dial indicator to measure backlash
of one pinion gear while holding side gear toward case. See Fig. 60
. Backlash should be .002-.008" (.05-
.20 mm).
5. If backlash exceeds specification, install thrust washers of different thickness. DO NOT overtighten the
vise. See SIDE GEAR THRUST WASHER SPECIFICATIONS
table. Perform same procedure
described in step 4 for front differential right case. See Fig. 60
.
SIDE GEAR THRUST WASHER SPECIFICATIONS
ID MarkThickness - In. (mm)
A.0394 (1.000)
B.0413 (1.050)
C.0433 (1.100)
D.0453 (1.150)
E.0472 (1.200)
F.0492 (1.250)
G.0512 (1.300)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 60: Measuring Front Differential Side Gear Backlash
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Install front differential left case to right case. Align match marks on left and right cases. Tighten Torx
screws to 24 ft. lbs. (33 N.m). Install front differential case to ring gear right case. Align flukes of discs in
hydraulic multi-plate clutch. Install No. 2 washer.
7. Clean ring gear left case contact surface. Heat ring gear to about 212°F (100°C) in an oil bath. DO NOT
heat ring gear above 230°F (110°C). Clean contact surface of ring gear with cleaning solvent. Quickly
install ring gear on differential case. Align match marks on ring gear left case and ring gear. Install ring
gear and left case on right case. Install 12 bolts. Align match marks on ring gear left and right cases.
Tighten bolts to 91 ft. lbs. (124 N.m).
8. Ensure front differential turns smoothly. Place speedometer drive gear on ring gear case. Install snap ring.
Install oil seal rings to ring gear right case. Install ring gear case sleeve. Install right case bearing outer
race.
DIFFERENTIAL ASSEMBLY (A-541E) DISASSEMBLY & REASSEMBLY

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Disassembly
1. Using appropriate puller, remove differential case side bearings. Remove speedometer drive gear. Place
reference marks on differential case and ring gear. Remove ring gear bolts. Using soft-face hammer,
remove ring gear.
2. Mount differential in vise. Using dial indicator, measure pinion gear backlash. See Fig. 61
. Backlash
should be .002-.008" (.05-.20 mm). From ring gear side of case, drive out pinion shaft roll pin. Remove
pinion shaft. Remove pinion gears, side gears and all thrust washers. See Fig. 62
. Examine all
components for wear and replace as needed.
Reassembly
1. Match side gears and pinion gears with corresponding thrust washers. Install gears in differential case.
Install pinion shaft. Check pinion gear backlash.
2. If backlash is not within specification, replace side gear thrust washers with matched set. Washers are
available in 3 thicknesses: .063" (1.60 mm), .067" (1.70 mm) and .071" (1.80 mm). Recheck backlash
after washers have been replaced.
3. Drive in pinion shaft roll pin. Ensure ring gear mounting surface is clean and free of burrs or scratches.
Heat ring gear in oil bath to 212°F (100°C). DO NOT exceed temperature. Install ring gear, aligning
reference marks made during disassembly. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Install speedometer drive gear. Press side bearing onto differential case. Lubricate
all moving parts with ATF.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 61: Measuring Differential Pinion Bearing Backlash (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
Helpmelearn
November-03-08 10:28:19 AMPage 82 © 2005 Mitchell Repair Information Company, LLC.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:19 AMPage 83 © 2005 Mitchell Repair Information Company, LLC.

Fig. 62: Exploded View Of Differential Assembly (A-541E)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TRANSAXLE REASSEMBLY
Reassembly (Differential & Drive Pinion)
1. Install NEW counter driven gear bearing (if necessary). Press in shaft bearing outer race into cage. Press
bearing onto drive pinion shaft. Install drive pinion into transaxle case. See Fig. 63
and Fig. 64 . Place
bearing cage onto drive pinion shaft. DO NOT damage oil seals with pinion shaft. Using brass drift and
hammer, lightly tap bearing cage into transaxle case until snap ring groove in bore is visible. Install snap
ring into bore.
2. On A-540E transaxle, install sensor rotor. On all transaxles, install oil slinger and NEW spacer (crush
sleeve). Install spacer with small end downward. Press outer race into case. Place transaxle case with
converter side facing down. Support drive pinion shaft with brass bar. See Fig. 65
. Using press, install
driven gear until bearing almost touches counter gear.
3. Install NEW lock nut. Secure gear from turning. Tighten nut to 207 ft. lbs. (280 N.m). Rotate gear both
directions while tightening nut. Using a INCH-lb. torque wrench, measure starting preload of drive
pinion.
4. Starting preload with new bearing should be 8.7-13.9 INCH lbs. (1.0-1.6 N.m). With used bearing,
preload should be 4.3-6.9 INCH lbs. (.5-.8 N.m). If preload exceeds specification, replace bearing spacer
(crush sleeve). DO NOT loosen nut to adjust starting preload.
5. If starting preload is less than specification, retighten shaft nut 115 INCH lbs. (13 N.m) at a time until
specified preload is reached. Maximum shaft nut torque is 260 ft. lbs. (353 N.m). If maximum torque is
exceeded while tightening shaft nut, replace bearing spacer. Repeat preload procedure. DO NOT loosen
nut to reduce preload. Stake lock nut.
6. Install apply gasket(s) in transaxle case. On A-540E and A-541E transaxles, place outer race and selected
adjusting shim on right side bearing. On all transaxles, place differential case in transaxle case. On A-
540E and A-541E transaxles, ensure shim is properly installed. On A-540H transaxle, ensure ring gear
mount case sleeve and outer race are properly installed.
7. On all transaxles, ensure bearing contact surfaces of differential (carrier) cover and transaxle case are oil
free. Apply appropriate sealer to case and carrier cover. Install cover. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
. NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts, and sliding
surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should
be replaced. Ensure ends of snap rings are not aligned with cut-outs and are
installed correctly in groove. If a worn bushing is to be replaced, replacement
must be made with the subassembly containing that bushing. Check thrust
bearings and races for wear or damage. Use petroleum jelly to hold parts in
place. Replace parts as necessary. Soak clutch plates in ATF for 15 minutes
prior to installation. For clutch disc and plate quantity, see CLUTCH DISC &
PLATE QUANTITY table.
NOTE: For thrust bearing and race location and identification, see Fig. 73
and Fig. 74 .

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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8. Install left bearing retainer by tapping with soft-faced hammer while keeping carrier centered with
retainer. Tighten bolts to 14 ft. lbs. (19 N.m). Seat bearings by turning differential assembly several
times.
9. Using a INCH-lb. torque wrench, measure total preload. See Fig. 17
. Drive pinion starting preload with
new bearings should be 2.2-3.8 INCH lbs. (.2-.4 N.m) greater than drive pinion shaft preload previously
measured in step 4 .
10. If used bearings are used, preload should be 1.2-1.9 INCH lbs. (.1-.2 N.m) greater than drive pinion shaft
preload previously measured. If preload exceeds specifications, replace adjusting shim in left bearing
retainer. Remove left bearing retainer. Remove bearing race from retainer. Select shim from
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM SELECTION
table.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM SELECTION
11. Install selected shim in retainer. Install bearing race. Install left bearing retainer by tapping with soft-
faced hammer while keeping carrier centered with retainer. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Recheck total starting preload.
12. If starting preload is within specification, remove left bearing retainer. Apply appropriate sealant to
retainer mounting surface. Apply thread sealer to bolts. Install retainer.
13. Place oil baffle on left bearing retainer. Press in oil seal until flush with surface of retainer. Apply sealant
to right retainer. Coat bolt threads with sealer. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Install drive pinion cap to converter side of transaxle case.
ID MarkThickness - In. (mm)
0.0787 (2.000)
1.0807 (2.050)
2.0827 (2.100)
3.0846 (2.150)
4.0866 (2.200)
5.0886 (2.250)
6.0906 (2.300)
7.0925 (2.350)
8.0945 (2.400)
9.0965 (2.450)
A.0984 (2.500)
B.1004 (2.550)
C.1024 (2.600)
D.1043 (2.650)
E.1063 (2.700)
F.1083 (2.750)
G.1102 (2.800)
H.1122 (2.850)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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November-03-08 10:28:20 AMPage 85 © 2005 Mitchell Repair Information Company, LLC.

Fig. 63: Exploded View Of Final Drive Components (A-540H)
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 10:28:20 AMPage 86 © 2005 Mitchell Repair Information Company, LLC.