TOYOTA RAV4 1996 Service Repair Manual

Fig. 40: Locating A-540E Lower Valve Body (Top) Check Balls
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 57 © 2005 Mitchell Repair Information Company, LLC.

Fig. 41: Locating A-540E Lower Valve Body (Bottom) Check Balls
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 58 © 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
Helpmelearn
November-03-08 10:28:18 AMPage 59 © 2005 Mitchell Repair Information Company, LLC.

Fig. 43: Identifying A-540H 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 10:28:19 AMPage 60 © 2005 Mitchell Repair Information Company, LLC.

Fig. 44: Locating A-540H Valve Body Check Balls
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly (Valve Body Assembly A-541E)

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

1. Install check ball and vibrating stopper to upper valve body. See Fig. 45 . Install oil strainers and check
ball to lower valve body (top). See Fig. 46
. Position No. 1 gasket against upper valve body. See Fig. 48 .
Place separator plate and No. 2 gasket on No. 1 gasket.
2. Hold gasket and plate assembly against upper valve body. Turn assembly over and install on lower valve
body assembly. Align bolt holes and install bolts. See Fig. 49
.
3. Install 3 check balls in lower valve body cover No. 2. See Fig. 34
. Place gaskets and separator plate on
valve body. Secure in place with screws. Install oil strainer, check balls and vibrating stopper in lower
valve body (bottom). See Fig. 47
. Install lower valve body cover No. 2. Align bolt holes and install bolts.
See Fig. 49
.
4. Install oil strainer and check valve in lower valve body. Install lower valve body cover No. 1 with gaskets
and separator plate. Install bolts. Tighten all retaining bolts to specification. See TORQUE
SPECIFICATIONS .
5. Install pressure relief valve. Tighten 3 upper valve body bolts. Install OD brake accumulator assembly.
Install lock plate. Install all solenoids.
Fig. 45: Locating A
-541E Upper Valve Body Check Balls

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:19 AMPage 62 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 46: Locating A
-541E Lower Valve Body (Top) Check Balls
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 63 © 2005 Mitchell Repair Information Company, LLC.

Fig. 47: Locating A-541E Lower Valve Body (Bottom) Check Balls
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 64 © 2005 Mitchell Repair Information Company, LLC.

Fig. 48: Identifying A-541E 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 10:28:19 AMPage 65 © 2005 Mitchell Repair Information Company, LLC.

Fig. 49: Locating A-541E Valve Body Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
OVERDRIVE UNIT DISASSEMBLY & REASSEMBLY

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:19 AMPage 66 © 2005 Mitchell Repair Information Company, LLC.