manual transmission TOYOTA RAV4 1996 Service Repair Manual

TRANSMISSION SERVICING - A/T
1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal & Installation
REMOVAL & INSTALLATION
MANUAL
AUTOMATIC
Removal (Avalon)
1. Disconnect negative battery cable. Remove battery, battery tray, air cleaner assembly and air cleaner case.
Disconnect throttle valve cable from throttle body. Remove cruise control actuator with mounting
bracket.
2. Raise and support vehicle. Disconnect necessary electrical connectors and ground cables for transaxle
removal. Disconnect shift cable and oil cooler lines at transaxle. Remove shift cable clamp bracket from
transaxle.
3. Remove front (radiator side) engine mount shock absorber-to-lower frame assembly bolts. Remove front
(radiator side) engine mount-to-lower frame assembly bolts/nuts. Remove starter.
4. Remove front (radiator side) exhaust manifold brace from rear of exhaust manifolds. Brace fits between
rear of exhaust manifold and front of transaxle.
5. Remove upper transaxle-to-cylinder block bolts. Support engine with hoist. Steering gear assembly must
be supported in place during transaxle removal. Secure steering gear assembly to the engine hoist using
an attaching strap placed at each end of steering gear assembly.
6. Remove front wheels. Remove front exhaust pipe located between exhaust manifolds and rear exhaust
pipe. Drain transaxle fluid. Remove axle shafts from transaxle. See FWD AXLE SHAFTS article in
DRIVE AXLES.
7. Disconnect shift control cable from mounting bracket. Remove rear (firewall side) engine mount-to-lower
frame assembly bolts/nuts. Remove transaxle mount-to-transaxle bolts at driver's side end of transaxle.
8. Remove stabilizer bar mount bracket-to-lower frame assembly bolts. Remove steering gear assembly-to-
lower frame assembly bolts/nuts. Support lower frame assembly with floor jack. Lower frame assembly is
located below the en
gine and transaxle. NOTE: For manual transmission/transaxle removal and installation procedures, see
appropriate CLUTCHES article.
WARNING:Ensure negative battery cable is disconnected at least 90 seconds before
working on vehicle to prevent air bag deployment.
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.

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


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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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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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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compressed air and remove piston. See Fig. 15. Remove inner snap ring.
Fig. 10: Exploded View Of Accumulator Piston Assemblies

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.NOTE: If manual shift linkage is damaged or needs to be disassembled, see MANUAL
SHIFT LINKAGE under COMPONENT DISASSEMBLY & REASSEMBLY.

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 24 © 2005 Mitchell Repair Information Company, LLC.

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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Fig. 65: Installing Driven Pinion
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly (Transaxle)
1. Check operation of parking lock pawl. Ensure counter driven gear is locked when manual valve lever is in
"P" range. Install "O" rings on 1st and reverse brake piston. Install 1st and reverse brake piston in case.
Push piston into bore of case, facing spring seat upward.
2. Install piston return spring. Using appropriate spring compressor, compress return spring. See Fig. 16
.
Install snap ring. Ensure snap ring is fully seated and centered by 3 lugs on spring retainer. Ensure snap
ring end gap is not aligned with spring retainer claw. Install center snap ring.
3. Install overdrive brake and overdrive clutch apply gaskets over appropriate case opening (ports). Install
overdrive brake drum to case. Install NEW case
gasket. Align each bolt hole in gasket case. Install

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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November-03-08 10:28:20 AMPage 96 © 2005 Mitchell Repair Information Company, LLC.