transmission TOYOTA RAV4 1996 Service Service Manual

TACOMA
TORQUE SPECIFICATIONS (TACOMA)
TERCEL
TORQUE SPECIFICATIONS (TERCEL)
Turbo41 (56)
Starter Bolt27 (37)
Torque Converter Bolt
Non-Turbo30 (41)
Turbo40 (54)
Transmission Crossmember Bolt18 (24)
Transmission-To-Cylinder Block Bolt
14-mm (4 Bottom Bolts)27 (37)
17-mm53 (72)
INCH Lbs. (N.m)
Floor Crossmember Brace Bolt115 (13.0)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt
2.4L 4-Cyl. & 2.7L 4-Cyl.54 (73)
3.4L V661 (83)
Drive Shaft Center Bearing Assembly-To-Crossmember Bolt27 (37)
Drive Shaft Flange Bolt/Nut54 (73)
Front Differential Assembly Rear Mount Bolt (4WD)80 (109)
Front Differential Assembly Rear Mount To-Crossmember Nut (4WD)64 (87)
Stabilizer Bar Link-To-Lower Control Arm Nut (4WD)51 (69)
Stabilizer Bar Mounting Bracket-To-Frame Bolt (4WD)19 (26)
Starter Bolt29 (39)
Stiffener Plate Bolt (2WD 2.4L 4-Cyl)27 (37)
Transmission Crossmember Bolt/Nut (4WD)48 (65)
Transmission-To-Cylinder Block Bolt53 (72)
Transmission Mount-To-Transmission Crossmember Bolt (4WD)14 (19)
Torque Converter Bolt30 (41)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt65 (88)
Exhaust Pipe Bolt46 (62)
Front (Radiator Side) Transaxle Mount Bolt36 (49)
Rear (Firewall) Engine Mount Assembly-To-Body Bolt
Outside Small Bolts (2)59 (80)

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

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T100
TORQUE SPECIFICATIONS (T100)
4RUNNER
TORQUE SPECIFICATIONS (4RUNNER)
Center Large Bolts (3)68 (92)
Rear (Firewall) Engine Mount Through-Bolt48 (65)
Starter Bolt29 (39)
Torque Converter Bolt20 (27)
Transaxle-To-Cylinder Block Bolt
Upper Bolt47 (64)
Lower Bolt(1)
Wheel Lug Nut76 (103)
(1)For bolt tightening specifications, see Fig. 9 and Fig. 10 .
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt61 (83)
Drive Shaft Center Bearing Assembly-To-Crossmember Bolt (4WD)27 (37)
Drive Shaft Flange Bolt/Nut (4WD)
Front Drive Shaft54 (73)
Rear Drive Shaft56 (76)
Stabilizer Bar-To-Lower Control Bolt/Nut (4WD)18 (25)
Stabilizer Bar Mounting Bracket-To-Frame Bolt (4WD)22 (30)
Starter Bolt29 (39)
Stiffener Plate Bolt27 (37)
Transmission Crossmember Bolt (4WD)70 (95)
Transmission-To-Cylinder Block Bolt53 (72)
Transmission Mount-To-Transmission Crossmember Bolt 4WD13 (18)
Torque Converter Bolt30 (41)
ApplicationFt. Lbs. (N.m)
Drive Plate-To-Crankshaft Bolt
2.7L 4-Cyl.55 (74)
3.4L V661 (83)
Drive Shaft Flange Bolt/Nut55 (74)
Front Exhaust Pipe-To-Exhaust Manifold Nut46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut36 (48)
Rear Transmission Mount-To-Transmission Bolt48 (65)
Rear Transmission Mount-To-Transmission Crossmember Bolt
2WD14 (19)

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

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4WD13 (18)
Stabilizer Bar Mounting Bracket-To-Frame Bolt (3.4L V6)18 (25)
Stabilizer Bar-To-Lower Control Arm Nut (3.4L V6)51 (69)
Starter Bolt29 (39)
Torque Converter Bolt30 (41)
Transmission Crossmember-To-Frame Through-Bolt48 (65)
Transmission-To-Cylinder Block Bolt52 (71)
INCH Lbs. (N.m)
Transmission Shift Lever Assembly Bolt (4WD)52 (5.9)
Transmission Shift Lever Control Rod Nut (2WD)113 (10.0)

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

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1997-99 AUTOMATIC TRANSMISSIONS
Toyota A-540E, A-540H & A-541E Overhaul
APPLICATION
TRANSMISSION APPLICATIONS
IDENTIFICATION
Vehicle Identification Number (VIN) is used for correct application of component parts and assemblies. VIN is
stamped on vehicle identification number plate, located at top left corner of dash and on certification label,
located on driver's door jam.
GEAR RATIOS
GEAR RATIOS NOTE: 1999 Lexus ES300 is equipped with a U140E automatic transaxle. For diagnosis
of this transaxle, see LEXUS U140E & U140F OVERHAUL article or LEXUS
U140E & U140F ELECTRONIC CONTROLS article.
Vehicle ApplicationTransmission Model
Lexus
ES300A-541E
Toyota
AvalonA-541E
Camry (V6) LE, SE & XLEA-541E
Camry Solara (V6) SE & SLEA-541E
RAV4 4WDA-540H
SiennaA-540E
NOTE: RAV4 is equipped with a transfer case. For transfer case overhaul procedures,
see appropriate TRANSFER CASES article in AXLE SHAFTS & TRANSFER
CASES.
CAUTION: All models are equipped with a Supplemental Restraint System (SRS).
When servicing vehicle, use care to avoid accidental air bag deployment.
All SRS electrical connections and wiring harness are covered by Yellow
insulation. SRS-related components are located in steering column, center
console, instrument panel and lower panel on instrument panel. DO NOT
use electrical test equipment on these circuits. If necessary, deactivate
SRS before servicing components. See AIR BAG DEACTIVATION
PROCEDURES article in GENERAL INFORMATION.

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

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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DESCRIPTION
The A-540H 4WD transaxle has a center differential and electronic transfer case attached. Transaxle internal
components are the same or similar to the A-540E and A-541E transaxles. Transaxle has 4 shift solenoids in the
valve body to control engagement speed and throttle pressure for shift feel. Torque is distributed to front and
rear wheels at all times to maximize traction of 4WD vehicle.
The A-540E and A-541E transaxles feature a torque converter with lock-up clutch, 4-speed planetary gear unit,
differential, hydraulic control system, shift solenoids and electronic control system. The A-541E transaxle has
an additional shift solenoid in the valve body to control engagement speed and throttle pressure for shift feel. A
shift lock mechanism is used to minimize possibility of incorrect operation of transaxle.
LUBRICATION
On all models except RAV4 4WD, transaxle uses D-II or DEXRON-III transmission fluid. On RAV4 4WD,
transaxle uses type "T" or type "T"-IV transmission fluid. For transaxle refill capacities, see TRANSAXLE
CAPACITIES table.
TRANSAXLE CAPACITIES
TRANSAXLE CAPACITIES
GearRatio
1st2.810
2nd1.549
3rd1.000
OD.734
Reverse2.296
ApplicationQts. (L)
Lexus ES300
Drain & Refill
19973.7 (3.5)
19984.1 (3.9)
Dry Refill7.1 (6.8)
Toyota
Avalon & Camry
Drain & Refill
19973.7 (3.5)
1998-994.1 (3.9)
Dry Refill7.1 (6.8)
Camry Solara
Drain & Refill5.0 (4.8)
Dry Refill7.1 (6.8)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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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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Fig. 2: Locating Valve Body Assembly Bolts (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. 3: Locating Manual Valve Body Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TROUBLE SHOOTING
SYMPTOM DIAGNOSIS
Fluid Discolored Or Smells Burnt
Fluid contaminated. Torque converter faulty. Transaxle faulty.
Vehicle Does Not Move In Any Forward Gear Or Reverse
Check manual valve, parking lock pawl, primary regulator valve, overdrive (OD) one-way clutch, OD direct
clutch, OD brake, front planetary gear, rear planetary gear and OD planetary gear.
Vehicle Does Not Move In Any Forward Gear
Check forward clutch, No. 2 one-way clutch, 1st and reverse brake, 2nd coast brake, 2nd brake and direct
NOTE: For electronic diagnosis and component testing of A-540E, A-540H and A-541E
transaxles, see appropriate TOYOTA ELECTRONIC CONTROLS article. For
diagnosis and testing of shift lock system, See TOYOTA & LEXUS SHIFT LOCK
SYSTEM article. For transaxle component locations, see Fig. 4
.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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clutch.
Vehicle Does Not Move In Reverse ("R")
Check 1-2 shift valve, 2-3 shift valve, 2nd coast brake, front planetary gear, rear planetary gear, direct clutch,
OD direct clutch and 1st and reverse brake.
No 1-2 &/Or 2-3 Upshift
Check Throttle Position (TP) sensor circuit, No. 1 and No. 2 shift solenoid circuit, Vehicle Speed Sensor (VSS)
circuit, Electronic Control Transmission Electronic Control Module (ECT ECM), 1-2 shift valve, 2-3 shift
valve, 2nd brake, direct clutch and No. 1 one-way clutch.
No 3-O/D Upshift
Check OD switch and OD OFF indicator switch circuit, OD cancel signal circuit, No. 1 and No. 2 shift solenoid
circuit, VSS, Engine Coolant Temperature (ECT) circuit, ECT ECM, 3-4 shift valve and OD brake.
No O/D-3 Downshift
Check No. 1 and No. 2 shift solenoid valve, VSS circuit, OD cancel signal circuit, ECT ECM and 3-4 shift
valve.
No 3-2 &/Or 2-1 Downshift
Check No. 1 and No. 2 shift solenoid valve, VSS circuit, TP sensor circuit, ECT ECM, 2-3 shift valve, 1-2 shift
valve and 2nd coast brake.
No Torque Converter Lock-Up
Check shift solenoid valve SL circuit, TP sensor circuit, VSS circuit, OD cancel circuit, brakelight circuit, ECT
circuit, ECT ECM, lock-up relay valve and torque converter clutch.
Torque Converter Lock-Up Will Not Release
Check shift solenoid valve SL circuit, TP sensor circuit, brakelight circuit, ECT ECM circuit, lock-up relay
valve and torque converter clutch.
Shift Speeds Too High Or Too Low
Check TP sensor circuit, VSS circuit, shift solenoid valve SL circuit, OD cancel signal circuit, pattern select
switch circuit and ECT ECM.
Harsh Engagement Neutral To Reverse
Check direct clutch accumulator, direct clutch, throttle valve and 1st and reverse brake.
Harsh Engagement Neutral To Drive

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