TOYOTA RAV4 1996 Service Repair Manual

piston. If piston does not come out, remove piston with needle-nose pliers. Remove oil seal rings (if
necessary).
Inspection
Inspect clutch piston. Shake piston to ensure check ball is free. Ensure valve does not leak by applying low
pressure compressed air. Replace oil seal rings (if removed). DO NOT spread ring ends more than required for
installation. Inspect discs, plates and flanges.
Reassembly
1. Coat NEW "O" rings with ATF. Install "O" rings on piston. Press piston into drum with cup side up.
Ensure "O" ring is not damaged.
2. Install return springs, retainer and snap ring in drum. Compress retainer using compressor. Using pliers,
install snap ring in groove. Ensure end gap of snap ring is not aligned with spring retainer claw.
3. Install plates, discs and flange. Install flange with flat end facing inward. Install outer snap ring. Ensure
end gap of ring is not aligned with cut-outs in clutch drum.
4. Check piston stroke. 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 less than specification,
replace flange. Flange is available in thicknesses of .091" (2.30 mm) and 1.06" (2.70 mm) for A-540E
and A-541E transaxles or .110" (2.80 mm), .118" (3.00 mm), .126" (3.20 mm), .134" (3.40 mm)
and .142" (3.60 mm) for A-540H transaxle.
Fig. 22: Checking Forward Clutch Piston Stroke

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. 23: Exploded View Of Forward Clutch

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
FRONT PLANETARY GEAR DISASSEMBLY & REASSEMBLY
Disassembly
1. Check operation of No. 1 one-way clutch. Holding sun gear input drum (shell), turn hub. Hub should turn
freely clockwise and should lock when turned counterclockwise. See Fig. 24
.
2. While turning hub clockwise, remove No. 1 one-way clutch from sun gear. Remove thrust washer from
sun gear input drum. Remove snap ring. Remove sun gear from drum. See Fig. 25
.
3. Using a screwdriver, remove ring gear snap ring. Remove ring gear flange from ring gear. Remove front
planetary gear from sun gear.
Inspection
1. Measure inside diameter of both sun gear bushings. Maximum inside diameter is .889" (22.59 mm) for A-
540E and A-541E transaxles or. 870" (22.09 mm) for A-540H transaxle. If inside diameter exceeds
specification, replace sun gear. Measure inside diameter of ring gear flange bushing. Maximum inside
diameter is 1.184" (30.08 mm) for A-540E and A-541E transaxles or .752" (19.10 mm) for A-540H
transaxle. If inside diameter exceeds specification, replace flange.
2. Measure planetar
y pinion gear thrust clearance. Standard clearance is .006-.022" (.16-.56 mm) for A-

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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540E and A-541E transaxles or .008-.020" (.20-.50 mm) for A-540H transaxle. See Fig. 26. Maximum
clearance is .024" (.61 mm) for all transaxles. If clearance exceeds specification, replace planetary gear
assembly.
Reassembly
Position flange into ring gear. Using a screwdriver, install snap ring. See Fig. 25 . Install shaft snap ring on sun
gear. Install sun gear input drum on sun gear. Install shaft snap ring. Install thrust washer on sun gear input
drum. While turning hub clockwise, slide one-way clutch on sun gear. Recheck operation of one-way clutch.
Fig. 24: Checking No. 1 One
-Way Clutch Operation
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. 25: Exploded View Of Front Planetary Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 26: Measuring Planetary Pinion Gear Thrust Clearance

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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REAR PLANETARY GEAR DISASSEMBLY & REASSEMBLY
Disassembly
1. Check operation of No. 2 one-way clutch. Hold outer race and turn rear planetary gear. Gear should turn
freely counterclockwise and should lock when turned clockwise. See Fig. 27
. Separate No. 2 one-way
clutch and rear planetary gear.
2. Remove thrust washer(s) from rear side of planetary gear. Remove snap rings and retainers from both
sides. Remove No. 2 one-way clutch from outer race. See Fig. 28
.
Inspection
Measure rear planetary pinion gear thrust clearance. Standard clearance is .006-.022" (.16-.56 mm) for A-540E
and A-541E transaxles or .008-.020" (.20-.50 mm) for A-540H transaxle. Maximum clearance is .024" (.61
mm) for all transaxles. Replace planetary gear assembly if clearance is excessive.
Reassembly
1. Install No. 2 one-way clutch into outer race. Face No. 2 one-way clutch flanged side toward outer race
shiny side. Install retainers and snap rings to both sides of No. 2 one-way clutch.
2. Install planetary gear into No. 2 one-way clutch facing inner race of planetary gear inward toward Black
side of outer race. Check operation of No. 2 one-way clutch. Coat thrust washers with petroleum jelly.
Install thrust washer on both sides of carrier. Ali
gn tab of washers with hollow of carrier.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 27: Checking No. 2 One-Way Clutch Operation
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 28: Exploded View Of Rear Planetary Gear

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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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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zDisassembly (A-540E)
zDisassembly (A-540H)
zDisassembly (A-541E)
zDisassembly & Reassembly
(Upper Valve Body - A-540E, A-540H & A-541E)
zDisassembly & Reassembly
(Lower Valve Body - A-540E, A-540H & A-541E)
zReassembly (Valve Body Assembly - A-540E)
zReassembly (Valve Body Assembly - A-540H)
zReassembly (Valve Body Assembly - A-541E)
Disassembly (A-540E)
1. Remove No. 1 and No. 2 solenoids. See Fig. 31 . DO NOT use a screwdriver to pry up solenoid(s).
Remove lock-up solenoid. Remove "O" ring(s) from solenoid(s).
2. Remove OD brake accumulator assembly. Remove check ball on No. 1 plate. 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 check balls, retainers and pins in lower valve bod
y.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 31: Exploded View Of Valve Body Assembly (A-540E)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (A-540H)

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 46 © 2005 Mitchell Repair Information Company, LLC.