TOYOTA RAV4 1996 Service Repair Manual

bolts with Three Bond (1324) sealer. Install and tighten nuts and bolts to 51 ft. lbs. (69 N.m). Install
breather hose to driven pinion bearing cage and transaxle upper cover.
28. On all transaxles, install cooler line union and elbow. Install elbow at right angles to bottom of case.
Install torque converter. Ensure converter is full of ATF before installation. Check installed position by
measuring installed depth from edge of case. See Fig. 72
. Distance should be .539" (13.7 mm).
Fig. 72: Measuring Torque Converter Installed Depth

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 10:28:20 AMPage 97 © 2005 Mitchell Repair Information Company, LLC.

Fig. 73: Identifying Thrust Bearing & Race Locations (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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November-03-08 10:28:20 AMPage 98 © 2005 Mitchell Repair Information Company, LLC.

Fig. 74: Identifying Thrust Bearing & Race Locations (A-540E & A-541E)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CLUTCH DISC & PLATE SPECIFICATIONS

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 99 © 2005 Mitchell Repair Information Company, LLC.

CLUTCH DISC & PLATE QUANTITY (1)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ComponentDiscPlate
OD Direct Clutch22
Forward Clutch55
Direct Clutch33
2nd Brake33
1st & Reverse Brake
A-540E77
A-541E66
OD Brake33
(1)Information for A-540H transaxle is not available from manufacturer.
ApplicationFt. Lbs. (N.m)
Counter Drive Gear Lock Nut207 (280)
Differential
Carrier Cover Bolt29 (39)
Front Right Case-To-Front Left Case Torx Screw24 (33)
Left Case-To-Right Case Bolt46 (63)
Left Side Bearing Retainer Bolt14 (19)
Right Retainer Bolt14 (19)
Drive Plate Bolt61 (83)
Oil Cooler Pipe Union Bolt20 (27)
Oil Pump Bolt16 (22)
Overdrive Case-To-Transaxle Case Bolts18 (25)
Ring Gear-To-Differential Case Bolts91 (124)
Transfer Case-To-Transaxle Bolt & Nut51 (69)
INCH Lbs. (N.m)
Accumulator-To-Cover Bolt89 (10)
Manual Valve Bolt97 (11)
Oil Pan Bolt
A-540E & A-541E43 (4.9)
A-540H69 (7.8)
Oil Pump Body-To-Stator Shaft Bolt89 (10)
Oil Strainer Bolt97 (11)
Parking Lock Pawl Bracket Bolt65 (7.4)
Park Neutral Position Switch
Bolt48 (5.4)

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 100 © 2005 Mitchell Repair Information Company, LLC.

TRANSAXLE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS
Nut61 (6.9)
Solenoid Bolt58 (6.6)
Speed Sensor Bolt48 (5.4)
Transfer Case Adjusting Lock-Plate Bolt64 (7.2)
Upper Valve Body-To-Lower Valve Body Bolt58 (6.6)
Valve Body-To-Transaxle Case Bolt97 (11)
ApplicationIn. (mm)
Bushing Inside Diameter (Maximum)
Direct Clutch
A-540E & A-541E1.900 (48.27)
A-540H1.853 (47.07)
Oil Pump Body1.503 (38.18)
OD Direct Clutch.871 (22.13)
Planetary Ring Gear Flange
A540E & A-541E1.184 (30.08)
A-540H.752 (19.10)
Sun Gear
A-540E & A-541E.889 (22.59)
A-540H.870 (22.09)
Stator Shaft.849 (21.57)
Clutch Pack Clearances
1st & Reverse Brake
A-540E.033-.081 (.85-2.05)
A-540H.041-.085 (1.04-2.16)
A-541E.076-.106 (1.92-2.68)
End Play
Differential (A-540H).007-.32 (.18-.82)
Input Shaft
A-540E & A-541E.010-.035 (.25-.90)
A-540H.012-.035 (.30-.90)
Intermediate Shaft.019-.059 (.47-1.50)
Intermediate Shaft Protrusion Length (A-540H)10.059 (255.50)
Oil Pump (Standard Measurements)
Body Clearance Of Driven Gear.0028-.0059 (.070-.150)
Tip Clearance Of Driven Gear.0043-.0055 (.110-.140)
Gear Side Clearance.0008-.0020 (.020-.050)
Piston Stroke

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 101 © 2005 Mitchell Repair Information Company, LLC.

Direct Clutch
A-540E & A-541E.036-.053 (.91-1.35)
A-540H.044-.058 (1.11-1.47)
Forward Clutch
A-540E & A-541E.071-.087 (1.79-2.21)
A-540H.056-.072 (1.41-1.82)
2nd Coast Brake.079-.138 (2.00-3.50)
OD Direct Clutch.069-.098 (1.75-2.49)
OD Planetary Pinion Gear Thrust Clearance (A-540H).006-.022 (.16-.56)
Planetary Pinion Gear Thrust Clearance
A-540E & A-541E.006-.022 (.16-.56)
A-540H.008-.020 (.20-.50)
Pinion Gear Backlash.002-.008 (.05-.20)
Torque Converter Runout (Maximum)
Drive Plate.008 (.20)
Sleeve.012 (.30)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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TRANSMISSION SERVICING - A/T
AUTOMATIC TRANSMISSION SERVICING Toyota
APPLICATION
AUTOMATIC TRANSMISSION APPLICATIONS
ModelTransmission/Transaxle
AvalonA541E
Camry
2.2L 4-Cyl.A140E
3.0L V6A541E
Celica
1.8L (7A-FE) 4-Cyl.A246E
2.2L (5S-FE) 4-Cyl.A140E
Corolla
1.6L (4A-FE) 4-Cyl.A131L
1.8L (7A-FE) 4-Cyl.A245E
Land CruiserA343F
MR2
1995 Models
2.2L Non-TurboA241E
PaseoA244E
Pickup
1995 Models
2WD
2.4L 4-Cyl.A43D
3.0L V6A340E
4WD
2.4L 4-Cyl.A340F
3.0L V6A340H
Previa
1995 Models
Non-Supercharged
2WDA46DE
All-Trac 4WDA46DF
Supercharged
2WDA340E
All-Trac 4WDA340F
1996 Models
2WDA340E

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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LUBRICATION
SERVICE INTERVALS
Severe Service (All Models)
Under severe conditions such as trailer towing, police, taxi, local delivery service or operating under dusty
conditions, replace transmission fluid and differential fluid ever
y 15,000 miles or 12 months.
All-Trac 4WDA340F
RAV4
1996 Models
2WDA241E
4WDA540H
Supra(1) A340E
Tacoma
2WD
2.4L (2RZ-FE) 4-Cyl.A43D
3.4L (5VZ-FE) V6A340E
4WD
2.7L (3RZ-FE) 4-Cyl.A340F
3.4L (5VZ-FE) V6A340F
Tercel
3-SpeedA132L
4-SpeedA242L
T100
2WDA340E
4WDA340F
4Runner
1995 Models
2WD
3.0L V6A340E
4WD
2.4L 4-Cyl. (2) A340F
3.0L V6A340H
1996 Models
2WDA340E
4WDA340F
(1)Transmission in turbo models contains a different electronic control system than the non-turbo
models.
(2)Applies only to Canada models.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Avalon, Camry, Celica 2.2L 5S-FE, Corolla 1.6L 4A-FE & Tercel With 3-Speed
Check transmission fluid level and transmission/differential fluid level every 15,000 miles or 24 months.
Transmission/differential fluid reservoir is independent from the transmission. Normal operating conditions
service interval is not available.
Celica 1.8L 7A-FE, Corolla 1.8L 7A-FE, MR2, Paseo, RAV4 & Tercel With 4-Speed, Land Cruiser, Pickup, Previa,
Supra, Tacoma, T100 & 4Runner
Check transmission fluid level every 15,000 miles or 24 months. Differential fluid reservoir is incorporated with
the transmission. Normal operating conditions service interval is not available.
CHECKING FLUID LEVEL
Transmission
1. Drive vehicle until engine and transmission reach normal operating temperature. Park vehicle on level
surface and apply parking brake. With engine idling and brakes applied, move gearshift from Park
through Low and back to Park.
2. Check fluid level on transmission dipstick. Fluid level should be in HOT range marked on dipstick. Add
proper type of fluid if necessary. See RECOMMENDED FLUID
under LUBRICATION. DO NOT
overfill transmission.
Transmission/Differential (Avalon, Camry, Celica 2.2L 5S-FE, Corolla 1.6L 4A-FE & Tercel 3-Speed)
Remove filler plug. See Fig. 1 -3. Fluid should be level with bottom edge of filler plug hole. If fluid is low, fill
with proper type fluid until fluid is level with filler plug opening. See RECOMMENDED FLUID
under
LUBRICATION. Reinstall filler plu
g. NOTE: When checking fluid level for the transmission, if vehicle has been operating in
heavy traffic, towing a trailer or at high speeds in hot weather, wait 30 minutes
before checking the fluid level.
NOTE: Some models have a transmission/differential unit. On these models the
differential lubrication is separate from the transmission fluid. It must be
checked and filled separately.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Tuesday, August 18, 2009 7:18:46 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Identifying Transmission/Differential Drain & Filler Plugs (Avalon & Camry 3.0L V6)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
Microsoft
Tuesday, August 18, 2009 7:18:46 PMPage 4 © 2005 Mitchell Repair Information Company, LLC.