Cv axle TOYOTA RAV4 1996 Service Workshop Manual

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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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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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 23: Exploded View Of Forward Clutch

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
FRONT PLANETARY GEAR DISASSEMBLY & REASSEMBLY
Disassembly
1. Check operation of No. 1 one-way clutch. Holding sun gear input drum (shell), turn hub. Hub should turn
freely clockwise and should lock when turned counterclockwise. See Fig. 24
.
2. While turning hub clockwise, remove No. 1 one-way clutch from sun gear. Remove thrust washer from
sun gear input drum. Remove snap ring. Remove sun gear from drum. See Fig. 25
.
3. Using a screwdriver, remove ring gear snap ring. Remove ring gear flange from ring gear. Remove front
planetary gear from sun gear.
Inspection
1. Measure inside diameter of both sun gear bushings. Maximum inside diameter is .889" (22.59 mm) for A-
540E and A-541E transaxles or. 870" (22.09 mm) for A-540H transaxle. If inside diameter exceeds
specification, replace sun gear. Measure inside diameter of ring gear flange bushing. Maximum inside
diameter is 1.184" (30.08 mm) for A-540E and A-541E transaxles or .752" (19.10 mm) for A-540H
transaxle. If inside diameter exceeds specification, replace flange.
2. Measure planetar
y pinion gear thrust clearance. Standard clearance is .006-.022" (.16-.56 mm) for A-

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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540E and A-541E transaxles or .008-.020" (.20-.50 mm) for A-540H transaxle. See Fig. 26. Maximum
clearance is .024" (.61 mm) for all transaxles. If clearance exceeds specification, replace planetary gear
assembly.
Reassembly
Position flange into ring gear. Using a screwdriver, install snap ring. See Fig. 25 . Install shaft snap ring on sun
gear. Install sun gear input drum on sun gear. Install shaft snap ring. Install thrust washer on sun gear input
drum. While turning hub clockwise, slide one-way clutch on sun gear. Recheck operation of one-way clutch.
Fig. 24: Checking No. 1 One
-Way Clutch Operation
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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REAR PLANETARY GEAR DISASSEMBLY & REASSEMBLY
Disassembly
1. Check operation of No. 2 one-way clutch. Hold outer race and turn rear planetary gear. Gear should turn
freely counterclockwise and should lock when turned clockwise. See Fig. 27
. Separate No. 2 one-way
clutch and rear planetary gear.
2. Remove thrust washer(s) from rear side of planetary gear. Remove snap rings and retainers from both
sides. Remove No. 2 one-way clutch from outer race. See Fig. 28
.
Inspection
Measure rear planetary pinion gear thrust clearance. Standard clearance is .006-.022" (.16-.56 mm) for A-540E
and A-541E transaxles or .008-.020" (.20-.50 mm) for A-540H transaxle. Maximum clearance is .024" (.61
mm) for all transaxles. Replace planetary gear assembly if clearance is excessive.
Reassembly
1. Install No. 2 one-way clutch into outer race. Face No. 2 one-way clutch flanged side toward outer race
shiny side. Install retainers and snap rings to both sides of No. 2 one-way clutch.
2. Install planetary gear into No. 2 one-way clutch facing inner race of planetary gear inward toward Black
side of outer race. Check operation of No. 2 one-way clutch. Coat thrust washers with petroleum jelly.
Install thrust washer on both sides of carrier. Ali
gn tab of washers with hollow of carrier.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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UPPER VALVE BODY VALVE SPRING SPECIFICATIONS
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540E)
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-540H)
UPPER VALVE BODY VALVE SPRING SPECIFICATIONS (A-541E)
Disassembly & Reassembly (Lower Valve Body A-540E, A-540H & A-541E)
1. When disassembling lower 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 lower valve bod
y valve spring free height. Replace any spring if specification is exceeded. See
ApplicationColorFree Height - In. (mm)
2nd Coast Modulator ValveBrown1.083 (27.50)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Downshift PlugYellow1.012 (25.70)
Throttle ValvePurple1.209 (30.70)
Throttle Modulator ValveOrange.854 (21.70)
Cut-Back ValveRed.858 (21.80)
No. 1 Accumulator Control ValveYellow1.106 (28.10)
Lock-Up Relay ValveGreen1.047 (26.60)
ApplicationColorFree Height - In. (mm)
2nd Coast Modulator ValveLight Blue1.126 (28.60)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Downshift PlugYellow1.173 (29.80)
Throttle ValvePurple1.209 (30.70)
Throttle Modulator ValveOrange.854 (21.70)
Cut-Back ValveRed.858 (21.80)
No. 1 Accumulator Control ValveBlue.992 (25.20)
Lock-Up Relay ValveGreen1.047 (26.60)
ApplicationColorFree Height - In. (mm)
Lock-Up Relay ValveYellow1.055 (26.80)
2nd Coast Brake Orifice Control ValveWhite.976 (24.80)
Throttle ValveGreen1.240 (31.50)
Downshift PlugNone.591 (15.00)
Low Coast Modulator ValvePurple.795 (20.20)
NOTE: On A-540H transaxle, line pressure changes according to part of plunger sleeve
which comes into contact with retainer. When reassembling lower valve body,
align retainer in same position.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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3. Remove differential side gears, side thrust washers, differential spider, differential pinions and pinion
washers from differential left case. See Fig. 56
.
4. Using a hammer and screwdriver, remove oil seal. Remove oil baffle from left bearing retainer. Drive out
outer race and adjusting shim from left bearing retainer with a hammer and brass drift. Remove right oil
seal from retainer.
Reassembly
1. Install right oil seal to retainer. Drive in NEW oil seal until seal surface is flush with surface of retainer.
Coat oil seal lip with grease.
2. Install original adjusting shim and bearing outer race to left bearing retainer. Shim should
be .0945" (2.400 mm). Press outer race into left retainer. Install oil baffle and oil seal after adjusting
differential side bearing preload. See TRANSAXLE REASSEMBLY
.
3. Assemble differential case. Coat all sliding and rotating surfaces with ATF before assembly. Install thrust
washer to side gear. Install pinions and thrust washers to spider. Install side gear and spider with pinions
to differential left case. Using a dial indicator, measure side gear backlash while holding one pinion
against carrier casing. See Fig. 60
. Backlash should be .002-.008" (.05-.20 mm). Install side gear and
spider with pinions to right side of differential case. Check pinion gear backlash.
4. Select side gear thrust washer which ensures backlash is within specification. Side gear thrust washers are
available in thicknesses from .0315" (.80 mm) to .0551" (1.40 mm) in .004" (.10 mm) increments. Select
washers of the same size for both sides. Install speedometer driven gear.
5. Align match marks on differential cases. Using plastic hammer, carefully tap differential right case. Using
a Torx wrench, install and tighten 16 Torx screws to 46 ft. lbs. (63 N.m).
6. Clean differential case contact surface with cleaning solvent. Heat ring gear to about 212°F (100°C) in an
oil bath. DO NOT heat ring above 230°F (110°C). Clean contact surface of ring gear with cleaning
solvent. Quickly install ring gear on differential case. Tighten bolts to 91 ft. lbs. (124 N.m). Install right
and left side bearin
g to differential case.

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1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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case. Using A/T Tool Set (09350-32014) and arbor press, remove bearing inner race. Using Bearing
Replacer (09316-60010) and arbor press, install NEW ring gear mounting right case bearing.
9. Use hammer and screwdriver to remove oil seal from ring gear mounting left case. Remove oil baffle
from left bearing retainer. Use hammer and brass bar to drive out outer race and adjusting shim from left
bearing retainer. Place adjusting shim into left bearing retainer. Use either original shim or shim with
thickness of .0945" (2.400 mm). Use A/T Tool Set (09350-32014) and arbor press to install outer race
and shim. Install oil baffle and oil seal after adjusting differential side bearing preload. See
TRANSAXLE REASSEMBLY
.
Reassembly
1. Coat 4 "O" rings with ATF. Install "O" rings on reaction sleeve and pistons. Install No. 1 piston, No. 2
piston and reaction sleeve to ring gear mounting right case.
2. Place return spring on piston. Install A/T Tool Set (09350-32014) on piston return spring retainer.
Compress spring with arbor press. Install snap ring.
3. Install plates and discs, starting with plate, alternating with disc and ending with disc. Install flange with
flat end facing downward. Install snap ring. Check operation of clutch pistons. Plug one hole with your
hand. Apply compressed air into other hole. Ensure pistons move. Install No. 1 thrust washer.
4. Install following parts into front differential left case: side gear thrust washer, side gear, 4 differential
pinion gears, 4 pinion gear thrust washers and differential spider. Use a dial indicator to measure backlash
of one pinion gear while holding side gear toward case. See Fig. 60
. Backlash should be .002-.008" (.05-
.20 mm).
5. If backlash exceeds specification, install thrust washers of different thickness. DO NOT overtighten the
vise. See SIDE GEAR THRUST WASHER SPECIFICATIONS
table. Perform same procedure
described in step 4 for front differential right case. See Fig. 60
.
SIDE GEAR THRUST WASHER SPECIFICATIONS
ID MarkThickness - In. (mm)
A.0394 (1.000)
B.0413 (1.050)
C.0433 (1.100)
D.0453 (1.150)
E.0472 (1.200)
F.0492 (1.250)
G.0512 (1.300)

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