length TOYOTA RAV4 1996 Service Repair Manual

against knuckle when bolt is tightened. Tighten wheel speed sensor and brake components to
specification. See TORQUE SPECIFICATIONS
.
ADJUSTMENTS
BRAKE BOOSTER PUSH ROD
1. Install adjusting gauge on master cylinder with master cylinder gasket in place. Lower adjusting gauge
pin until pin slightly touches master cylinder piston. See Fig. 12
. Turn adjusting gauge upside-down and
install on power brake booster.
2. Measure clearance between brake booster push rod and adjusting gauge pin head. See Fig. 12
. Measured
clearance should be zero. If clearance is not zero, adjust brake booster push rod length until push rod
lightly touches adjusting gauge pin head.
Fig. 12: Adjusting Master Cylinder Push Rod

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
BRAKE PEDAL HEIGHT
1. Remove instrument panel lower finish panel. Brake pedal height is measured from face of brake pedal
pad to asphalt sheet under carpet. See Fig. 13
.
2. Brake pedal height should be 6.19-6.58" (157.2-167.2 mm). To adjust brake pedal height, disconnect
stoplight switch connector. Loosen stoplight switch lock nut and remove switch. Loosen lock nut on
brake pedal push rod. Adjust pedal height by turning push rod.
3. After adjusting brake pedal height, tighten push rod lock nut. Adjust stoplight switch. See STOPLIGHT
SWITCH . Check and adjust brake pedal free play. See BRAKE PEDAL FREE PLAY.

1999 Toyota RAV4
1999-2000 BRAKES Anti-Lock - RAV4
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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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select a new piston rod. Piston stroke should be .079-.138" (2.00-3.50 mm). Piston rod is available in lengths of
3.748" (95.20 mm) and 3.791" (96.30 mm).
Reassembly
Install plate washer and inner spring to piston rod. Install "E" ring while pushing piston. Apply ATF to oil seal
ring. Install oil seal ring to piston. DO NOT spread ring ends more than necessary for installation.
Fig. 30: Exploded View Of 2nd Coast Brake

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
VALVE BODY ASSEMBLY DISASSEMBLY & REASSEMBLY
The followin
g headings are used to identify valve bodies and component procedures:
CAUTION: When disassembling valve body assembly, DO NOT damage or deform
plate that overhangs valve body. Throttle pressure is changed according
to number of rings behind throttle valve. Some valve bodies DO NOT have
adjusting rings. Note which step at end of plunger sleeve is in contact with
valve body before disassembly. Line pressure is affected by plunger
location.

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

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.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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ACCUMULATOR SPRING SPECIFICATIONS
21. Install 2nd brake apply gasket. Install throttle cable and solenoid wire. Place valve body on transaxle.
While holding cam down with hand, slip cable end in slot. Lower valve body into position. DO NOT
entangle solenoid wiring. Install valve body bolts. Ensure proper length and location of bolts. See Fig. 1
.
Finger tighten all bolts. Tighten bolts in crisscross pattern to specification. See TORQUE
SPECIFICATIONS .
22. Install 1st and reverse brake apply tube. Install connector clamp and tube retainer. Connect solenoid
connectors. Using a plastic hammer, install oil tubes. DO NOT bend or damage tubes. Place manual valve
body on transmission. Align manual lever with pin of manual shaft lever. Lower manual valve body into
position. Ensure proper length and location of bolts. See Fig. 3
. Finger tighten bolts. Evenly tighten bolts
in crisscross pattern.
23. Install detent spring. Ensure proper length and location of each bolt. Finger tighten bolts. Check for
correct operation of manual valve lever. Ensure lever is touching center of detent spring tip roller.
24. Install tube bracket and oil strainer. Install magnets in oil pan. Ensure magnets do not interfere with oil
tubes. Install oil pan with NEW gasket. Install vehicle speed sensor with "O" ring (as applicable). Install
speed sensor connector. Install throttle cable retaining plate. Install solenoid wire.
25. Install transaxle case upper cover. Install direct clutch speed (T/M revolution) sensor (if equipped). Install
park/neutral position switch to manual valve shaft. Install NEW locking plate. Tighten nut and stake with
locking plate. Adjust switch by aligning groove and neutral basic line. Tighten bolts. Install manual shift
lever.
26. On A-540H transaxle, install NEW snap ring to shaft groove and install differential side gear intermediate
shaft. See Fig. 63
. Keeping intermediate shaft on pinion shaft of differential, measure shaft protrusion
length from transaxle case surface to end of shaft. Protrusion length should be 10.059" (255.50 mm).
27. Install NEW apply gasket on differential carrier cover. Install transfer case assembly to transaxle. Apply
seal packing Three Bond (1281) or Loctite (518) to contacting surface of transaxle case. Coat threads of
ApplicationColorFree Length - In. (mm)
A-540E
Direct ClutchYellow/Purple2.173 (55.20)
2nd BrakeBlue/White2.701 (68.60)
Forward ClutchBlue/Green2.803 (71.20)
A-540H
Direct ClutchRed2.008 (51.00)
2nd BrakeBlue/White2.701 (68.60)
Forward ClutchPink2.433 (61.80)
A-541E
Direct ClutchYellow/Purple2.039 (51.08)
2nd Brake
1997Brown/Pink3.035 (77.10)
1998
InnerNone3.472 (88.20)
OuterNone2.768 (70.30)
Forward ClutchNone2.898 (73.60)

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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TRANSAXLE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS
Nut61 (6.9)
Solenoid Bolt58 (6.6)
Speed Sensor Bolt48 (5.4)
Transfer Case Adjusting Lock-Plate Bolt64 (7.2)
Upper Valve Body-To-Lower Valve Body Bolt58 (6.6)
Valve Body-To-Transaxle Case Bolt97 (11)
ApplicationIn. (mm)
Bushing Inside Diameter (Maximum)
Direct Clutch
A-540E & A-541E1.900 (48.27)
A-540H1.853 (47.07)
Oil Pump Body1.503 (38.18)
OD Direct Clutch.871 (22.13)
Planetary Ring Gear Flange
A540E & A-541E1.184 (30.08)
A-540H.752 (19.10)
Sun Gear
A-540E & A-541E.889 (22.59)
A-540H.870 (22.09)
Stator Shaft.849 (21.57)
Clutch Pack Clearances
1st & Reverse Brake
A-540E.033-.081 (.85-2.05)
A-540H.041-.085 (1.04-2.16)
A-541E.076-.106 (1.92-2.68)
End Play
Differential (A-540H).007-.32 (.18-.82)
Input Shaft
A-540E & A-541E.010-.035 (.25-.90)
A-540H.012-.035 (.30-.90)
Intermediate Shaft.019-.059 (.47-1.50)
Intermediate Shaft Protrusion Length (A-540H)10.059 (255.50)
Oil Pump (Standard Measurements)
Body Clearance Of Driven Gear.0028-.0059 (.070-.150)
Tip Clearance Of Driven Gear.0043-.0055 (.110-.140)
Gear Side Clearance.0008-.0020 (.020-.050)
Piston Stroke

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Transmission (Pickup 4WD W/3.0L V6 & 1995 4Runner 4WD W/V6)
1. Remove transmission oil pan drain plugs from transmission. See Fig. 4 . Allow fluid to fully drain. If
replacing transmission oil strainer, remove transmission oil pan and gasket.
2. Remove bolts, transmission oil strainer and gasket (if equipped). Thoroughly clean transmission oil pan.
Using NEW gasket (if equipped), install transmission oil strainer. Install and tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
3. Using NEW gasket, install transmission oil pan (if removed). Install and tighten bolts to specification See
TORQUE SPECIFICATIONS
. Fill transmission through dipstick tube to specified capacity using
recommended fluid. See RECOMMENDED FLUID
under LUBRICATION.
4. Ensure vehicle is on a level surface. Apply parking brake. Start engine and apply brakes. Move gearshift
from Park through Low and back to Park.
5. Check fluid level on transmission dipstick. Add proper type fluid so fluid level is at the COOL range
marked on the dipstick. Operate vehicle to normal operating temperature and recheck. See CHECKING
FLUID LEVEL under LUBRICATION. CAUTION: When removing transmission oil strainer, note bolt size and length
for reassembly reference.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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