Motor oil TOYOTA RAV4 1996 Service User Guide

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
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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2ND BRAKE DISASSEMBLY & REASSEMBLY
Disassembly & Inspection
Apply compressed air to oil hole in 2nd brake piston to remove piston. Remove 2 "O" rings from piston. Inspect
discs, plates and flange. See Fig. 29
.
Reassembly
Coat NEW "O" rings with ATF. Install 2 "O" rings on piston. Press piston into drum, being careful not to
damage "O" rings.
Fig. 29: Exploded View Of 2nd Brake

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2ND COAST BRAKE DISASSEMBLY & REASSEMBLY
Disassembly
Remove oil seal ring from piston. Remove piston rod "E" ring while pushing piston with needle-nose pliers.
Remove inner spring, plate washer and piston rod. See Fig. 30
.
Inspection
Inspect brake band lining condition. If brake band is serviceable but piston stroke is not within standard value,

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 43 © 2005 Mitchell Repair Information Company, LLC.

select a new piston rod. Piston stroke should be .079-.138" (2.00-3.50 mm). Piston rod is available in lengths of
3.748" (95.20 mm) and 3.791" (96.30 mm).
Reassembly
Install plate washer and inner spring to piston rod. Install "E" ring while pushing piston. Apply ATF to oil seal
ring. Install oil seal ring to piston. DO NOT spread ring ends more than necessary for installation.
Fig. 30: Exploded View Of 2nd Coast Brake

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
VALVE BODY ASSEMBLY DISASSEMBLY & REASSEMBLY
The followin
g headings are used to identify valve bodies and component procedures:
CAUTION: When disassembling valve body assembly, DO NOT damage or deform
plate that overhangs valve body. Throttle pressure is changed according
to number of rings behind throttle valve. Some valve bodies DO NOT have
adjusting rings. Note which step at end of plunger sleeve is in contact with
valve body before disassembly. Line pressure is affected by plunger
location.

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 44 © 2005 Mitchell Repair Information Company, LLC.

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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November-03-08 10:28:18 AMPage 47 © 2005 Mitchell Repair Information Company, LLC.

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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November-03-08 10:28:18 AMPage 48 © 2005 Mitchell Repair Information Company, LLC.

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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November-03-08 10:28:18 AMPage 49 © 2005 Mitchell Repair Information Company, LLC.

Fig. 42: Locating A-540E & A-540H Valve Body Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly (Valve Body Assembly A-540H)
1. Position NEW No. 1 gasket, No. 1 separator plate and NEW No. 2 gasket on upper valve body. For
gasket identification, see Fig. 43
. Ensure check balls are correctly installed. See Fig. 44 . Place upper
valve body with No. 1 plate and gaskets on lower valve body.
2. Hold upper valve body, No. 1 plate and gaskets so they do not separate. Align each bolt hole in valve
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. Install NEW lower valve body cover gaskets and No. 2 plate.
Install NEW 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 2 bolts. Install shift solenoids valves
SL and ST. 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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November-03-08 10:28:18 AMPage 59 © 2005 Mitchell Repair Information Company, LLC.

Disassembly (Overdrive Brake)
1. While pushing return spring, remove snap ring with a screwdriver. Remove piston return spring. Remove
plates, discs and flange. Note number and location of components. See Fig. 50
.
2. Remove piston from drum by applying compressed air to oil hole. See Fig. 51
. Ensure piston does not
tilt. Remove "O" rings from piston. Inspect disc, plate and flange. If discs are replaced, soak discs in ATF
for 15 minutes.
Reassembly (Overdrive Brake)
1. Install "O" rings on piston. Coat "O" rings with ATF. Install piston in drum. Ensure "O" ring is not
damaged. Install flange facing flat end upward.
2. Install discs and plates. Install cushion plate with rounded end upward. Install piston return spring
assembly. Install snap ring into case. Ensure end gap of snap ring is not aligned with cutouts.
Fig. 50: Exploded View Of Overdrive Assembly

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 10:28:19 AMPage 67 © 2005 Mitchell Repair Information Company, LLC.

Fig. 55: Checking Distance Between Overdrive Gear & Case
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (Overdrive Case)
Remove snap ring. Remove retaining plate and 2 springs. Remove OD direct clutch accumulator piston from
overdrive case. Remove "O" ring from piston. Spread 2 oil seal rings apart and remove rings.
Reassembly (Overdrive Case)
Spread rings and install in grooves. After installing oil seal rings, check for smooth movement. Coat "O" ring
with ATF. Install NEW "O" ring on accumulator piston. Install accumulator piston, springs, retaining plate and
snap ring.
DIFFERENTIAL ASSEMBLY (A-540E) DISASSEMBLY & REASSEMBLY
Disassembly
1. Using appropriate puller, remove differential case side bearings. Place match marks on both differential
case and ring gear. Remove 16 bolts. Tap ring gear with a plastic hammer to remove gear.
2. Place match marks on differential right and left case. Remove 16 Torx screws. Using a plastic hammer,
tap out differential left case. Remove speedometer drive
gear from differential right case.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 56: Exploded View Of Differential Assembly (A-540E)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DIFFERENTIAL ASSEMBLY (A-540H) DISASSEMBLY & REASSEMBLY
Disassembly
1. Remove right case bearing outer race. See Fig. 57 . Use a dial indicator to measure differential end play.
End play should be .0071-.0323" (.180-.820 mm). See Fig. 58
. Remove ring gear mounting case sleeve.
Remove 4 oil seal rings from ring gear mounting right case. Remove snap ring and speedometer drive
gear.
2. Place match marks on ring gear mounting left case and right case. Remove bolts and left case. Place
match marks on ring gear and left case. Place left case on A/T Tool Set (09350-32014). Using a plastic
hammer, remove ring gear from left case.
3. Remove No. 2 thrust washer. Remove front differential left case from ring gear mounting right case.
Using a Torx wrench, remove screws from left case. Separate left and right cases. DO NOT scratch
contact surface of needle bearing.
4. Remove the following parts from front differential cases: 2 differential side gears and 2 side thrust
washers, differential spider, 4 differential pinions and 4 pinion washers.
5. Remove No. 1 thrust washer. Check operation of clutch pistons. Plug one hole in right case with your
hand. Apply compressed air into other hole and confirm pistons move. See Fig. 59
.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:19 AMPage 75 © 2005 Mitchell Repair Information Company, LLC.