air condition TOYOTA RAV4 1996 Service Owner's Guide

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. 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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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2ND BRAKE DISASSEMBLY & REASSEMBLY
Disassembly & Inspection
Apply compressed air to oil hole in 2nd brake piston to remove piston. Remove 2 "O" rings from piston. Inspect
discs, plates and flange. See Fig. 29
.
Reassembly
Coat NEW "O" rings with ATF. Install 2 "O" rings on piston. Press piston into drum, being careful not to
damage "O" rings.
Fig. 29: Exploded View Of 2nd Brake

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2ND COAST BRAKE DISASSEMBLY & REASSEMBLY
Disassembly
Remove oil seal ring from piston. Remove piston rod "E" ring while pushing piston with needle-nose pliers.
Remove inner spring, plate washer and piston rod. See Fig. 30
.
Inspection
Inspect brake band lining condition. If brake band is serviceable but piston stroke is not within standard value,

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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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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Replace shift lock solenoid if operating sound cannot be heard.
SHIFT LOCK SOLENOID RESISTANCE SPECIFICATIONS
KEY INTERLOCK SOLENOID
1. Disconnect electrical connector from key interlock solenoid. Using ohmmeter, measure resistance
between key interlock solenoid terminals. See WIRING DIAGRAMS
.
2. Replace key interlock solenoid if resistance is not 12-17 ohms. Apply battery voltage between of key
interlock solenoid terminals. Replace key interlock solenoid if operating sound cannot be heard.
SHIFT LOCK CONTROL SWITCH
Disconnect electrical connector from shift lock control switch. Using ohmmeter, check continuity between
specified terminals in relation to shift lever. See WIRING DIAGRAMS
. See SHIFT LOCK CONTROL
SWITCH CONTINUITY table. Replace switch if continuity is not as specified.
SHIFT LOCK CONTROL SWITCH CONTINUITY
CABLE OPERATED SHIFT LOCK SYSTEM CHECK
Sienna
Ensure shift lock cable does not interfere with wiring harness. Ensure ignition switch turns to LOCK position
when shift lever is in "P" position. Ensure brake pedal returns fully. Ensure shift lock is released when brake
pedal is depressed with ignition switch at ACC, ON or START position.
ADJUSTMENTS
PARKING LOCK CABLE
ApplicationOhms
Avalon, Camry, Camry Solara & Tacoma (A43D)30-35
Celica, Corolla, GS300, GS400 & 4Runner21-27
ES300 & RX30029-36
Land Cruiser, LS400, LX470, SC300, SC400 & Tacoma (A-340E/F)20-28
RAV426-33
NOTE: Continuity must be checked in accordance with position of release button on
shift lever and shift lever position.
Shift Lever Position & ConditionTerminals
Any Other Gear Except ParkP & P2
Park & Release Button Not PushedP & P1
Park & Release Button Is PushedP & P1 Or P & P2

1999 Toyota RAV4
1999 AUTOMATIC TRANSMISSIONS Toyota & Lexus Shift Lock System
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1999-2000 DRIVE AXLES
Center Differential Lock
DESCRIPTION & OPERATION
CENTER DIFFERENTIAL LOCK SYSTEM
The center differential lock system enables vehicle to have enough traction to move when one of the 4 wheels,
both front wheels or both rear wheels are off the ground or on a slippery surface.
Center differential lock system consists of control switch, differential lock control solenoids, differential lock
actuator, indicator switch, and integration relay. See Fig. 1
.
With control switch off, the center differential lock indicator light on instrument panel is off, along with
vacuum switching valves No. 1 and 2. Vacuum switching valve No. 1 draws vacuum from vacuum tank to
chamber "A" of the vacuum actuator. Vacuum switching valve No. 2 draws atmospheric air to chamber "B".
Under these conditions, the vacuum actuator diaphragm moves the rod, which moves the locking sleeve shift
fork and shaft, which causes the locking sleeve to disengage from the case. See Fig. 2
. During this time, the
center differential warning buzzer will sound. When the locking sleeve is completely disengaged, the warning
buzzer will turn off (free position).

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
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If cruise control operation is canceled by any canceling switch, vehicle set speed can be resumed and controlled
at the previously set speed by moving cruise control switch to RES/ACC (resume/accelerate) position. Set
speed, however, cannot be resumed if vehicle speed drops to less than 25 MPH, which clears cruise control
ECU set speed stored.
When cruise control switch is moved to RES/ACC (resume/accelerate) position while in cruise control mode,
actuator motor is energized to open engine throttle valve. Vehicle accelerates until switch is released. From then
on, cruise control ECU stores new vehicle speed and maintains that speed.
Cancel Position
When cruise control switch is moved to CANCEL position, a cancellation signal is sent to cruise control ECU
disabling cruise control operation. Previous vehicle set speed is stored in cruise control ECU memory.
CRUISE CONTROL ELECTRONIC CONTROL UNIT (ECU)
Cruise control Electronic Control Unit (ECU) constantly monitors and compares set speed with actual vehicle
speed from input sensors. When vehicle speed is greater than set speed, cruise control ECU activates actuator
motor to close engine throttle valve, reducing vehicle speed. When vehicle speed drops to less than set speed,
cruise control ECU activates actuator motor to open engine throttle valve, increasing vehicle speed.
Cruise control ECU includes a self-diagnostic function. If cruise control system is canceled by any condition
other than driver operation, cruise control ECU assumes a malfunction has occurred and may set a
corresponding trouble code.
VEHICLE SPEED SENSOR
Vehicle speed sensor is mounted on transaxle. Vehicle speed sensor rotor shaft is driven by a gear on transaxle
output shaft. For each shaft rotation, vehicle speed sensor sends a 4-pulse signal to instrument cluster and cruise
control ECU. Cruise control ECU calculates vehicle speed from this pulse signal.
SELF-DIAGNOSTIC SYSTEM
When vehicle is in cruise control mode, system will cancel due to a malfunction in actuator, vehicle speed
sensor or other cruise circuit. When cruise control functions are canceled due to a malfunction, CRUISE
indicator light will blink, indicating a trouble code is stored in cruise control ECU memory. See DIAGNOSTIC
TROUBLE CODE DEFINITIONS table under SELF-DIAGNOSTIC SYSTEM.
If a fault or symptom is present, but no trouble codes were set, a system function test can be performed. See
CRUISE CONTROL FUNCTION TEST
under TROUBLE SHOOTING.
Before proceeding with cruise control system self-diagnostic system, ensure basic inspection of system
connectors and wiring harnesses has been performed. If no faults were found during basic inspection, proceed
with self-diagnostic system.
NOTE: Intermittent failures may cause CRUISE indicator light to flicker or come on.
Light will go out after fault goes away. Fault may or may not be present at time

1999 Toyota RAV4
1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - RAV4
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Fig. 3: Identifying Defogger Switch Harness Connector Terminals (MR2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DEFOGGER SWITCH TIMER CIRCUIT
Camry & Camry Solara
Disconnect defogger switch 6-pin connector. Use DVOM to check circuits as specified. See DEFOGGER
TIMER CIRCUIT TEST (CAMRY & CAMRY SOLARA) table. If readings are not as specified, repair
circuit as necessary. If readings are as specified, replace defogger switch and retest system.
DEFOGGER TIMER CIRCUIT TEST (CAMRY & CAMRY SOLARA)
Check Between Ground &
Pin No.
(1) ConditionSpecification
3AllContinuity
4IGN In LOCK/ACCZero Volts
4IGN In ONBattery Voltage

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Rear Window & Mirror Defoggers
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Corolla & Tercel
Disconnect defogger switch 6-pin connector. Use DVOM to check circuits as specified. See DEFOGGER
TIMER CIRCUIT TEST (COROLLA & TERCEL) table. If readings are not as specified, repair circuit as
necessary. If readings are as specified, replace defogger switch and retest system.
DEFOGGER TIMER CIRCUIT TEST (COROLLA & TERCEL)
ECHO
Disconnect defogger switch 4-pin connector. Use DVOM to check circuits as specified. See DEFOGGER
TIMER CIRCUIT TEST (ECHO) table. If readings are not as specified, repair circuit as necessary. If
readings are as specified, replace defogger switch and retest system.
DEFOGGER TIMER CIRCUIT TEST (ECHO)
Land Cruiser
Disconnect control panel 22-pin connector C9. See Fig. 4 and Fig. 12 . Use DVOM to check circuits as
specified. See CONTROL PANEL SWITCH CIRCUIT TEST (LAND CRUISER)
table. If readings are as
specified, replace switch and retest system. If readings are not as specified, repair circuit as necessary. If
readin
gs are as specified, replace defogger switch and retest system.
5IGN In LOCK/ACCZero Volts
5IGN In ONBattery Voltage
(1)See Fig. 9 .
Check Between Ground &
Pin No.
(1) ConditionSpecification
3AllContinuity
2IGN In LOCK/ACCZero Volts
2IGN In ONBattery Voltage
6IGN In LOCK/ACCZero Volts
6IGN In ONBattery Voltage
(1)See Fig. 9 .
Check Between Ground &
Pin No.
(1) ConditionSpecification
2AllContinuity
3IGN In LOCK/ACCZero Volts
3IGN In ONBattery Voltage
4Defogger Switch OffNo Continuity
4Defogger Switch OnContinuity
(1)See Fig. 11 .

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Rear Window & Mirror Defoggers
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