TOYOTA RAV4 1996 Service Repair Manual

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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Fig. 51: Removing Overdrive Brake Piston
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (Overdrive Direct Clutch)
1. Remove overdrive direct clutch from case. See Fig. 50 . Remove bearing and race from clutch drum and
case. Using a screwdriver, remove snap ring. Remove flanges, discs and plates. Note number and location
of components. Compress piston return spring and remove snap ring. Remove piston return spring.
2. Install drum in case. Apply compressed air to pressure apply hole. Remove OD direct clutch drum from
case. See Fig. 52
. If piston does not completely come out, use needle-nose pliers to remove piston.
Remove "O" rings from piston.
Inspection
Inspect check ball in piston for free movement by shaking piston. Ensure valve does not leak by applying low
pressure compressed air. If discs are replaced, soak discs in ATF for 15 minutes. Measure inside diameter of 2
direct clutch bushings. Maximum inside diameter is .871" (22.13 mm). If inside diameter exceeds specification,
replace direct clutch drum.
Reassembly (Overdrive Direct Clutch)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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1. Coat NEW "O" ring with ATF. Install "O" ring on piston. Press piston in drum with cup side up. DO
NOT damage "O" ring. Install return spring and set snap ring in place. See Fig. 50
.
2. Set spring compressor block on spring retainer and compress springs. Using a screwdriver, install snap
ring. Ensure end gap of ring is aligned with groove of clutch drum.
3. Install plates, discs and flange. Using a screwdriver, install snap ring. Ensure snap ring end gap is not
aligned with groove of clutch drum. Coat bearing with petroleum jelly and install race facing downward
toward clutch drum. Install overdrive clutch drum to case.
4. Measure piston stroke by applying and releasing 57-114 psi (4-8 kg/cm
2 ) of compressed air. Piston
stroke should be .069-.098" (1.75-2.49 mm). See Fig. 52
. Ensure piston moves freely. If piston does not
move, disassemble and inspect.
Fig. 52: Checking OD Direct Clutch Piston Stroke

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (Overdrive Counter Drive Gear)
1. Install overdrive direct clutch into one-way clutch. Hold overdrive direct clutch and turn intermediate
shaft. Shaft should turn freely clockwise and lock counterclockwise. See Fig. 53
. Remove overdrive
direct clutch.
2. Check counter drive gear preload. Hold overdrive planetary gear in a soft-jawed vise. DO NOT let
counter drive gear touch the vise. Using a spring gauge, measure preload. See Fig. 54
. Turn counter drive
gear right and left several times before measuring preload. Starting preload should be 2.1-3.4 lbs. (9.2-

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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15.3 N).
3. Remove snap ring and retaining plate. Remove overdrive one-way clutch and outer race as an assembly.
Remove one-way clutch from outer race, noting direction of one-way clutch.
4. Remove No. 3 planetary gear thrust washer. See Fig. 50
. Using a magnet, carefully remove 4 plugs from
planetary gear. Pry back lock washer with screwdriver. Hold shaft in soft-jawed vise. Loosen adjusting
nut. Remove nut and washer.
5. Using a bearing puller and arbor press, remove intermediate shaft bearing. Using press, remove counter
drive gear and front bearing together. Remove rear bearing using bearing puller and arbor press. Tag
bearings to show location for reassembly.
6. To remove overdrive planetary ring gear from counter drive gear, pull up ring gear while compressing
snap ring with needle-nose pliers. Remove snap ring from groove.
7. Remove ring gear from counter drive gear. Using a brass drift bar and hammer, drive outer races from
counter drive gear. Remove snap ring from counter drive gear. Tag races to show location for reassembly.
Inspection
Measure planetary pinion gear thrust clearance. Standard clearance is .006-.022" (.16-.56 mm). Maximum
clearance is .024" (.61 mm). If clearance is excessive, replace planetary gear assembly.
Reassembly (Overdrive Counter Drive Gear)
1. Install snap ring in counter drive gear. Install 2 outer races to both sides of counter drive gear. Press in
outer races until races touch snap ring.
2. Install snap ring to ring gear. While pushing down on ring gear, squeeze snap ring end with needle-nose
pliers. Install overdrive planetary ring gear into counter drive gear.
3. Install rear bearing on shaft. Press in bearing until side surface of inner race touches planetary carrier.
Install counter drive gear on shaft. Mesh ring gear with planetary pinions. Place front bearing on shaft.
Hold ring gear to prevent shaft from falling.
4. Press in bearing until there is slight play between bearings. Install intermediate shaft bearing. Press
bearing until bearing slightly touches front bearing of counter drive gear.
5. Place NEW locking washer and adjusting nut on intermediate shaft. Adjust preload of counter drive gear.
Holding shaft in a soft-jawed vise and using a tension gauge and lock nut wrench on adjusting nut, tighten
adjusting nut. See Fig. 54
.
6. Rotate counter drive gear right and left several times before measuring preload. Tighten adjusting nut
until preload is 2.1-3.4 lbs. (9.2-15.3 N). Bend locking washer tab until even with adjusting nut groove.
7. Install 4 plugs into pinion shaft. Install No. 3 thrust washer with groove facing overdrive case. Install one-
way clutch into outer race. Install retainers on both sides of one-way clutch. Install one-way clutch into
overdrive planetary gear. Ensure one-way clutch is installed in correct direction. Install retaining plate
and snap ring.
8. Hold overdrive direct clutch and turn intermediate shaft. Shaft should turn freely clockwise and lock
counterclockwise. See Fig. 53
. Remove overdrive direct clutch from one-way clutch.
9. While turning overdrive planetary gear clockwise, install gear on overdrive direct clutch. If overdrive
planetary gear is properly installed, clearance between counter drive gear and overdrive case will
be .94" (24.0 mm). See Fig. 55 .

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 53: Checking OD 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. 54: Checking Counter Drive Gear Preload
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 72 © 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.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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3. Remove differential side gears, side thrust washers, differential spider, differential pinions and pinion
washers from differential left case. See Fig. 56
.
4. Using a hammer and screwdriver, remove oil seal. Remove oil baffle from left bearing retainer. Drive out
outer race and adjusting shim from left bearing retainer with a hammer and brass drift. Remove right oil
seal from retainer.
Reassembly
1. Install right oil seal to retainer. Drive in NEW oil seal until seal surface is flush with surface of retainer.
Coat oil seal lip with grease.
2. Install original adjusting shim and bearing outer race to left bearing retainer. Shim should
be .0945" (2.400 mm). Press outer race into left retainer. Install oil baffle and oil seal after adjusting
differential side bearing preload. See TRANSAXLE REASSEMBLY
.
3. Assemble differential case. Coat all sliding and rotating surfaces with ATF before assembly. Install thrust
washer to side gear. Install pinions and thrust washers to spider. Install side gear and spider with pinions
to differential left case. Using a dial indicator, measure side gear backlash while holding one pinion
against carrier casing. See Fig. 60
. Backlash should be .002-.008" (.05-.20 mm). Install side gear and
spider with pinions to right side of differential case. Check pinion gear backlash.
4. Select side gear thrust washer which ensures backlash is within specification. Side gear thrust washers are
available in thicknesses from .0315" (.80 mm) to .0551" (1.40 mm) in .004" (.10 mm) increments. Select
washers of the same size for both sides. Install speedometer driven gear.
5. Align match marks on differential cases. Using plastic hammer, carefully tap differential right case. Using
a Torx wrench, install and tighten 16 Torx screws to 46 ft. lbs. (63 N.m).
6. Clean differential case contact surface with cleaning solvent. Heat ring gear to about 212°F (100°C) in an
oil bath. DO NOT heat ring above 230°F (110°C). Clean contact surface of ring gear with cleaning
solvent. Quickly install ring gear on differential case. Tighten bolts to 91 ft. lbs. (124 N.m). Install right
and left side bearin
g to differential 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
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November-03-08 10:28:19 AMPage 75 © 2005 Mitchell Repair Information Company, LLC.

Fig. 57: Exploded View Of Differential Assembly (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 10:28:19 AMPage 76 © 2005 Mitchell Repair Information Company, LLC.