transmission oil TOYOTA RAV4 1996 Service Owner's Manual

PASEO
TORQUE SPECIFICATIONS (PASEO)
PREVIA
TORQUE SPECIFICATIONS (PREVIA)
Oil Cooler Pipe Bolt102 (11.5)
Transmission Shift Control Rod Nut115 (13)
Transmission Shift Lever Boot Bolt48 (5.4)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt61 (83)
Front (Radiator Side) Transaxle Mount Bolt35 (47)
Intake Manifold Brace Bolt/Nut15 (20)
Rear (Firewall) Engine Mount Assy.-To-Body Bolt
Outside Small Bolts (2)58 (79)
Center Large Bolts (3)67 (91)
Stabilizer Bar Mounting Bracket-To-Frame Bolt14 (19)
Stabilizer Bar-To-Lower Control Arm Bolt13 (18)
Starter Bolt29 (39)
Torque Converter Bolt13 (18)
Transaxle Bracket-To-Rear (Firewall Side) Engine Mount Assembly Bolt47 (64)
Transaxle-To-Cylinder Block Bolt(1)
Wheel Lug Nut76 (103)
(1)For bolt tightening specifications, see Fig. 7 .
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt54 (73)
Drive Shaft Center Bearing Assembly-To-Body Bolt
4WD Front Drive Shaft27 (37)
Drive Shaft Flange Bolt/Nut
2WD54 (73)
4WD
Front Drive Shaft31 (42)
Rear Drive Shaft54 (73)
Exhaust Pipe Support Bracket Bolt
Exhaust Pipe Side32 (43)
Transmission Side37 (51)
Front Drive Shaft Bracket Bolt (4WD)
Lower Bolt41 (56)
Upper Bolt Nearest Starter30 (41)

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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ON-VEHICLE SERVICE
PARK/NEUTRAL POSITION (PNP) SWITCH
Removal & Installation
1. Disconnect park/neutral position (PNP) switch connector. Remove nut and disconnect shift control cable.
Remove nut, washer and manual shaft lever. Pry back locking tab on manual shaft washer and remove
nut. Remove 2 bolts and remove park/neutral position (PNP) switch.
2. Install PNP switch to manual shaft. Install 2 bolts finger tight. Install NEW locking plate. Install nut and
tighten to 61 INCH lbs. (6.9 N.m). Stake nut with locking plate. Install manual shaft lever, washer and
nut. Tighten nut to 115 INCH lbs. (13 N.m). Install shift control cable and nut. Tighten nut to 11 ft. lbs.
(15 N.m). Adjust switch by aligning groove and neutral basic line. Tighten 2 bolts to 48 INCH lbs. (5.4
N.m). Ensure engine starts in Park and Neutral.
THROTTLE CABLE
See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.
VALVE BODY ASSEMBLY
Removal
1. Clean exterior of transaxle. Remove oil pan plug. Drain transaxle. Remove oil pan and gasket. Discard
gasket. Remove oil strainer. Note location of magnets in oil pan. Remove magnets. Examine particles in
pan. Steel (magnetic) particles indicate bearing, gear, or plate wear. Brass (non-magnetic) particles
indicate bushing wear.
2. Remove tube bracket. Note location of oil tubes, and remove oil tubes. Disconnect solenoid wiring
harness connector(s). Remove manual detent spring. Remove manual valve. Disconnect throttle cable
from cam. Remove valve body assembly. Remove 2nd brake apply gasket.
Installation
1. Install NEW 2nd brake apply gasket. While holding cam down, slip cable end into slot. DO NOT tangle
RAV4
Drain & Refill3.5 (3.3)
Dry Refill7.4 (7.0)
Sienna
Drain & Refill3.7 (3.5)
Dry Refill6.9 (6.5)
CAUTION: Note bolt length and location during disassembly. Proper length bolts
must be installed to prevent case damage.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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solenoid wire. Install valve body assembly. Hand tighten valve body assembly retaining bolts. See Fig. 1
and Fig. 2 . Tighten all retaining bolts to specification. See TORQUE SPECIFICATIONS . Connect
solenoid wiring connector(s).
2. Align manual valve with pin on manual shaft lever. Lower manual valve body into position. Install 5
bolts finger tight. See Fig. 3
. Install detent spring. Ensure manual valve lever is in contact with center of
roller at tip of detent spring. Install 2 bolts finger tight. Tap oil tubes into position. DO NOT bend or
damage tubes during installation. Install oil tube bracket.
3. Install oil strainer. Install magnets in oil pan. Ensure magnets do not interfere with oil tubes. Install oil
pan and new gasket. Install drain plug with NEW washer gasket. Fill transaxle with ATF.
Fig. 1: Locating Valve Body Assembly Bolts (A
-540E & 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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HYDRAULIC PRESSURE TEST
Line Pressure Test
1. Ensure transmission fluid is at operating temperature. Raise and support vehicle. Remove transaxle case
test plug and install pressure gauge. See Fig. 5
. Lower vehicle and block all wheels.
2. Fully apply parking brake. Start engine. Apply brakes. Shift into "D" range. On A-540H transaxle, apply
battery voltage between ground and terminal No. 1 of shift solenoid valve ST connector. See Fig. 6
. On
all transaxles, measure line pressure at idle. Accelerate to full throttle. Measure line pressure at stall
speed. See appropriate LINE PRESSURE SPECIFICATIONS table.
3. On all models, repeat test in "R" range. DO NOT ground shift solenoid valve ST in "R" range.
4. If pressures exceed specifications in all ranges, regulator valve or throttle valve is faulty or throttle cable
is out of adjustment.
5. If pressures in all ranges are lower than specifications, oil pump, regulator valve, throttle valve or OD
direct clutch is faulty or throttle cable is out of adjustment.
6. If pressure is lower than specifications in "D" range only, forward clutch is faulty or "D" range circuit has
a fluid leak.
7. If pressure is lower than specifications in "R" range only, direct clutch is faulty, 1st and reverse brake is
faulty or "R" range circuit has a fluid leak.
LINE PRESSURE SPECIFICATIONS (A-540E)
LINE PRESSURE SPECIFICATIONS (A-540H) 1997
(1)
CAUTION: Hydraulic pressure test should be performed with transmission fluid
temperature of 122-176°F (50-80°C).
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed51-60 (3.6-4.2)
Stall Speed127-148 (8.9-10.4)
"R" Position
Idle Speed93-108 (6.5-7.6)
Stall Speed230-268 (16.1-18.8)
Selector PositionPressure - psi (kg/cm2 )
"D" Position
Idle Speed
With Solenoid Valve ST On76-102 (5.4-7.2)
With Solenoid Valve ST Off53-61 (3.7-4.3)
Stall Speed
With Solenoid Valve ST On192-225 (13.5-15.8)
With Solenoid Valve ST Off106-125 (7.5-8.8)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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TORQUE CONVERTER
ONE-WAY CLUTCH TEST
1. Insert a turning tool into inner race of one-way clutch. Install Tester (09350-32014) so that it fits in notch
of converter hub and other race of one-way clutch.
2. With torque converter in normal operating position, clutch should lock when turned counterclockwise and
should rotate freely and smoothly when turned clockwise. See Fig. 7
. If one-way clutch fails test in either
direction, clean converter. Retest clutch. If clutch fails test, replace converter.
Fig. 7: Testing Torque Converter One
-Way Clutch
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CONVERTER SLEEVE RUNOUT TEST
1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on
converter sleeve. See Fig. 8
. Rotate converter. If runout exceeds .012" (.30 mm), ensure converter is
properly mounted to drive plate.
2. If converter is properl
y mounted and runout exceeds specifications, replace torque converter. Mark NOTE: Torque converter is a sealed unit and must be serviced as complete assembly.
Perform following tests to check converter condition. Torque converter and oil
cooler lines must be thoroughly cleaned and flushed if transaxle fluid is
contaminated.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 9: Checking Drive Plate Runout
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
For transaxle removal procedure, see appropriate AUTOMATIC TRANSMISSION REMOVAL article in
TRANSMISSION SERVICING.
OVERHAUL
TRANSAXLE DISASSEMBLY
1. On A-540H, remove breather hose from drive pinion bearing cage. Remove bolts and nuts on transfer
case assembly. Remove transfer case assembly from transaxle. Remove apply gasket. Using
Remover/Installer (09520-32012), remove differential side gear intermediate shaft. See Fig. 63
.
2. On all transaxles, remove cooler pipe unions and/or elbows. Remove oil cooler pipes (if applicable).
Remove dipstick and filler tube. Remove manual shift lever. Pry back locking tab on manual shaft
NOTE: RAV4 is equipped with a transfer case. For transfer case overhaul procedures,
see TOYOTA A-540H transfer case article in AXLE SHAFTS & TRANSFER
CASES.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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washer. Remove nut and washer. Remove Park/Neutral Position (PNP) switch.
3. Remove throttle cable retaining bolt. Remove solenoid harness connector retaining bolt (if applicable).
Remove vehicle speed sensor mounted in differential cover. Remove sensor adapter. Remove direct
clutch speed (T/M revolution) sensor mounted to upper case cover (if equipped). Remove upper case
cover. Remove transaxle oil pan. Examine any contamination in pan to aid in diagnosis.
4. Remove oil stainer (filter) and oil pipe hold-down bracket. Remove manual valve body including detent
spring. Gently remove all oil pipes by prying up on end of pipe with screwdriver.
5. Disconnect solenoid harness connectors. Remove connector clamp and apply pipe retainer. Remove 1st
and reverse apply pipe. Remove valve body bolts. Remove wiring harness clamp. Disconnect throttle
cable from cam and remove valve body.
6. Remove throttle cable and solenoid wiring harness. Remove 2nd brake apply gasket. Loosen accumulator
cover bolts in crisscross pattern. Remove cover and gasket. Remove forward clutch accumulator. See Fi
g.
10 .
7. Remove remaining accumulators by applying 14 psi (1kg/cm
2 ) of air pressure to apply hole. See Fig.
11 . Cover accumulator bores with a rag when applying air.
8. Mark 2nd coast brake servo apply piston rod where it meets case. Apply 57-114 psi (4-8 kg/cm
2 ) of air
pressure to apply hole and measure piston rod travel (stroke). See Fig. 12
. Piston rod travel should
be .079-.138" (2.0-3.5 mm). If rod travel is not within specification, further inspect band during
disassembly.
9. Remove 2nd coast brake piston cover snap ring. Apply air to oil hole and remove cover and piston
assembly. See Fig. 12
. Remove oil pump bolts. Using appropriate puller, remove oil pump.
10. Remove direct clutch and forward clutch. Separate components and remove thrust washer. Remove thrust
bearings from front and rear of forward clutch. Push out 2nd coast brake band anchor pin. Remove band
and inspect.
11. Remove front planetary ring gear. Remove front planetary gear with thrust bearings on either side.
Remove thrust bearings. Remove sun gear shell with thrust washer.
12. Apply compressed air to 2nd brake piston port and check operation of 2nd brake. See Fig. 13
. Remove
2nd coast brake band guide. DO NOT separate band guide and bolt. Remove snap ring securing 2nd
brake drum. Remove drum.
13. Remove 2nd brake piston return spring. Remove No. 1 one-way clutch. Remove 2nd brake clutch discs,
plates and flange. Note number and location of components. Remove snap ring securing No. 2 one-way
clutch and rear planetary gear. See Fig. 14
. Remove components.
14. Remove thrust washer from rear planetary gear. Remove rear planetary ring gear with thrust bearing.
Apply air into appropriate passage to check 1st and reverse brake operation. See Fig. 15
.
15. Using feeler gauge, check pack clearance of 1st and reverse brake assembly. Clearance should be .033-
.081" (.85-2.05 mm) for A-540E transaxle, .041-.085" (1.04-2.16 mm) for A-540H transaxle, or .076-
.106" (1.92-2.68 mm) for A-541E transaxle. Remove snap ring securing 1st and reverse brake. Remove
1st and reverse brake discs, plates and flange. Note number and location of components.
16. From back of transaxle, remove 13 bolts securing overdrive unit. Using soft-faced hammer, tap around
outside of case until overdrive unit loosens and can be removed.
17. Remove overdrive (OD) planetary gear from transaxle case. Remove OD brake drum. See Fig. 14
.
Remove gaskets for OD clutch apply and OD brake apply ports.
18. Usin
g appropriate compressor, compress 1st and reverse piston. See Fig. 16 . Remove snap ring. Apply

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 16: Compressing 1st & Reverse Brake Piston Springs
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Differential & Drive Pinion Removal
1. Using INCH-lb. torque wrench, measure and record differential total preload. See Fig. 17 . Remove left
differential bearing retainer. Ensure case or retainer is not damaged if prying is necessary.
2. On A-540E and A-541E transaxles, remove right bearing retainer. On all transaxles, remove carrier cover
bolts in crisscross pattern. Remove cover. Remove apply port gasket at lower portion of case. Remove
differential assembly.
3. From converter side of case, remove drive pinion cap. Using INCH-lb. torque wrench, measure drive
pinion preload. See Fig. 17
. Starting preload should be 4.3-6.9 INCH lbs. (.5-.8 N.m). Subtract drive
pinion preload from total preload.
4. If difference is not 1.1-1.7 INCH lbs. (about .1 N.m), differential side bearing preload may not have been
within specification. Carefully inspect condition of all bearings and replace as needed. See appropriate
component disassembly and reassembly procedure under OVERHAUL.
5. Bend back locking washer securing nut on drive pinion shaft. Secure driven gear and remove nut. Using
appropriate puller, remove driven gear and bearing. Using appropriate 2-jaw puller, remove outer race,
spacer and oil slinger. On A-540E transaxle, remove sensor rotor.
6. On all transaxles, remove snap ring. Turn transaxle case, converter side facing up. Install appropriate bar
into hole in drive pinion. Press out drive pinion shaft. Remove bearing cage from drive pinion. Press off
bearing if replacement is needed.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Fig. 17: Checking Driven Pinion Preload Or Total Preload
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MANUAL SHIFT LINKAGE DISASSEMBLY & REASSEMBLY
Disassembly & Reassembly
1. Remove parking lock pawl bracket. Using hammer and chisel, cut collar on manual valve shaft. Remove
retaining spring. Drive out roll pin on shaft.
2. Slide out shaft from case and remove manual valve lever and parking lock rod. Remove shaft oil seal.
Remove pin, spring and parking lock pawl.
3. To assemble, reverse disassembly procedure. Use NEW collar. Lubricate seal before installing manual
valve lever shaft. Check operation of parking lock pawl.
OIL PUMP DISASSEMBLY & REASSEMBLY
Disassembly
Remove "O" ring and 2 oil seal rings from pump body and stator shaft. Remove clutch drum thrust washer from
stator shaft. Remove bolts attaching oil pump body and stator shaft. Identify top and bottom and keep parts in
order. Separate stator shaft and pump body. Mark gear locations for reassembly reference. See Fig. 18
. Remove
front seal.
Inspection

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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1. Check body clearance of driven gear. Push gear to one side of body. Measure body clearance. See Fig.
19 . Clearance should be .0028-.0059" (.070-.150 mm). Maximum clearance is .012" (.30 mm). If worn
beyond specification, replace pump body.
2. Check tip clearance of driven gear. Measure between gear teeth and crescent-shaped part of pump body.
See Fig. 19
. Tip clearance should be .0043-.0055" (.110-.140 mm). Maximum tip clearance is .012" (.30
mm). If tip clearance is greater than maximum specification, replace pump body.
3. Using a steel straightedge and feeler gauge, measure side clearance of both gears. See Fig. 19
. Clearance
should be .0008-.0020" (.020-.050 mm). Maximum side clearance is .004" (.10 mm). If worn beyond
specification, replace pump body. Drive and driven gears are available in different thicknesses. See OIL
PUMP DRIVE & DRIVEN GEAR SPECIFICATIONS table.
OIL PUMP DRIVE & DRIVEN GEAR SPECIFICATIONS
4. Measure inside diameter of oil pump body bushing. Maximum inside diameter is 1.503" (38.18 mm). If
inside diameter is greater than maximum specification, replace oil pump body. Measure inside diameter
of stator shaft bushing. Maximum diameter of stator shaft bushing is .849" (21.57 mm). If worn beyond
specification, replace stator shaft.
Reassembly
1. Install NEW oil seal. Seal is properly installed when it is flush with outer edge of pump body. Install
driven gear and drive gear. Ensure identifying marks are facing upward. Install stator shaft on pump
body. Align bolt holes. Install stator shaft-to-oil pump body bolts. Tighten bolts to specification. See
TORQUE SPECIFICATIONS
.
2. Align tab of washer with hollow of pump body. Install thrust washer. Install 2 oil seal rings on oil pump.
DO NOT spread ring ends more than required for installation. Ensure oil seal rings move freely. Turn
drive gear with screwdriver to ensure smooth rotation.
ID MarkThickness - In. (mm)
A-540E & A-541E
A.3717-.3723 (9.440-9.456)
B.3723-.3730 (9.456-9.474)
C.3730-.3736 (9.474-9.490)
A-540H
F.4209-.4212 (10.690-10.699)
G.4213-.4216 (10.700-10.709)
H.4217-.4220 (10.710-10.720)
J.4221-.4224 (10.721-10.730)
K.4225-.4228 (10.731-10.740)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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November-03-08 10:28:17 AMPage 31 © 2005 Mitchell Repair Information Company, LLC.