check oil TOYOTA RAV4 1996 Service Owner's Manual

Disassembly
1. Prior to disassembly, check piston stroke of direct clutch. Measure piston stroke by applying 57-114 psi
(4-8 kg/cm
2 ) of compressed air. See Fig. 20 . Piston stroke should be .036-.053" (.91-1.35 mm) for A-
540E and A-541E transaxles or .044-.058" (1.11-1.47 mm) for A-540H transaxle. If piston stroke is
greater than maximum, inspect each component.
2. Remove snap ring from clutch drum. Remove flange, discs and plates. Note number and location of
components. See Fig. 21
. Compress piston return springs and remove snap ring. Remove spring retainer.
Slide direct clutch onto oil pump. Remove piston by applying low pressure compressed air. See Fig. 20
.
Remove direct clutch from oil pump. Remove "O" ring from clutch piston.
Inspection
Shake piston to ensure direct clutch piston check ball is free. Ensure valve does not leak by applying low
pressure compressed air. Inspect discs, plates and flange. Measure inside diameter of direct clutch bushing.
Maximum inside diameter is 1.900" (48.27 mm) for A-540E and A-541E transaxles or 1.853" (47.07 mm) for
A-540H transaxle. If inside diameter is excessive, replace direct clutch.
Reassembly
1. Install NEW "O" rings on piston. Coat rings with ATF. Press piston in drum with cup side up. Ensure "O"
ring is not damaged. Install piston return springs. Install retainer and snap ring.
2. Install plates, discs and flange. Install flange with flat side facing inward. Install outer snap ring. Ensure
end gap of snap ring is not aligned with cut-outs in direct clutch drum.
3. Install direct clutch on oil pump. Check piston stroke. Using a dial indicator, measure piston stroke by
applying and releasing 57-114 psi (4-8 kg/cm
2 ) of compressed air. See Fig. 20 .
4. Piston stroke should be .036-.053" (.91-1.35 mm) for A-540E and A-541E transaxles or .044-.058" (1.11-
1.47 mm) for A-540H transaxle. If piston stroke is less than specification, replace flange. Flange is
available in thicknesses of .106" (2.70 mm) and .118" (3.00 mm) for A-540E and A-541E transaxles
or .102" (2.60 mm), .110" (2.80 mm) and .118" (3.00 mm) for A-540H transaxle.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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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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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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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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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

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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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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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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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 (top). See Fig. 40
. Install NEW lower valve body cover gaskets
and No. 2 plate. Install 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 3 bolts. Install lock-up solenoid. 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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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.

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