tow TOYOTA RAV4 1996 Service Repair Manual

Using Diagnosis Check Wire
1. Turn ignition switch to ACC or ON position. Wait about 20 seconds. Using Diagnosis Check Wiring
(09843-18020), connect terminals Tc and E1 of Data Link Connector (DLC1). See Fig. 14
. DLC1 is
located forward of right (passenger-side) front strut tower.
2. If AIR BAG warning light flashes 2 times per second, system is normal (normal code). If AIR BAG
warning light does not flash Diagnostic Trouble Codes (DTCs) or flashes DTCs without DLC1
connection, proceed to DTCS NOT DISPLAYED
under DIAGNOSTIC TESTS or DTCS
CONTINUOUSLY DISPLAYED under DIAGNOSTIC TESTS. If AIR BAG warning light is on
continuously and DTC is normal (flashes 2 times per second), source voltage is low. Go to SOURCE
VOLTAGE DROP under DIAGNOSTIC TESTS.
3. If AIR BAG warning light flashes, count number of flashes to determine DTCs that are set. For example,
DTC 12 is: FLASH, 1.5-second pause, FLASH, FLASH. If more than one DTC is displayed, a 2.5-
second pause will occur between each DTC. Lowest numbered DTC will be displayed first, followed by
next higher number DTC until all DTCs have been displayed.
4. After all DTCs are displayed, a 4-second pause will occur, and DTC display will be repeated. See
appropriate DTC under DIAGNOSTIC TESTS. After repairing, clear DTCs. See CLEARING CODES
.
Using Toyota Hand-Held Tester
Install Toyota hand-held tester to DLC1 or DLC3. DLC1 is located forward of right (passenger-side) front strut
tower. See Fig. 14
. DLC3 is located under left side of instrument panel, to right of steering column. Read DTC
by following prompts on tester. See tester operator's manual for instructions. NOTE: If DTCs other than those listed under DIAGNOSTIC TESTS
are displayed,
replace the air bag sensor assembly. If the air bag warning light does not
function as described, proceed to appropriate test under DIAGNOSTIC TESTS
.

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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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.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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November-03-08 10:28:18 AMPage 41 © 2005 Mitchell Repair Information Company, LLC.

1. Coat NEW "O" ring with ATF. Install "O" ring on piston. Press piston in drum with cup side up. DO
NOT damage "O" ring. Install return spring and set snap ring in place. See Fig. 50
.
2. Set spring compressor block on spring retainer and compress springs. Using a screwdriver, install snap
ring. Ensure end gap of ring is aligned with groove of clutch drum.
3. Install plates, discs and flange. Using a screwdriver, install snap ring. Ensure snap ring end gap is not
aligned with groove of clutch drum. Coat bearing with petroleum jelly and install race facing downward
toward clutch drum. Install overdrive clutch drum to case.
4. Measure piston stroke by applying and releasing 57-114 psi (4-8 kg/cm
2 ) of compressed air. Piston
stroke should be .069-.098" (1.75-2.49 mm). See Fig. 52
. Ensure piston moves freely. If piston does not
move, disassemble and inspect.
Fig. 52: Checking OD Direct Clutch Piston Stroke

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (Overdrive Counter Drive Gear)
1. Install overdrive direct clutch into one-way clutch. Hold overdrive direct clutch and turn intermediate
shaft. Shaft should turn freely clockwise and lock counterclockwise. See Fig. 53
. Remove overdrive
direct clutch.
2. Check counter drive gear preload. Hold overdrive planetary gear in a soft-jawed vise. DO NOT let
counter drive gear touch the vise. Using a spring gauge, measure preload. See Fig. 54
. Turn counter drive
gear right and left several times before measuring preload. Starting preload should be 2.1-3.4 lbs. (9.2-

1998 Toyota Avalon XLS
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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overdrive assembly over gasket to transaxle case. Coat threads of 23 mm bolts with sealer. See Fig. 66.
Tighten bolts to specification. See TORQUE SPECIFICATIONS
.
4. Check intermediate shaft end play (axial). See Fig. 67
. End play should be .019-.059" (.47-1.50 mm).
Ensure shaft turns smoothly. If end play is not within specification, check installation of intermediate
shaft.
5. Install rear planetary ring gear. Place bearing on ring gear. Coat thrust washer with petroleum jelly and
install on rear planetary gear. Install rear planetary gear. See Fig. 28
.
6. Install 1st and reverse brake discs, plates and flange. See Fig. 14
. Start with plate, alternating with disc,
and ending with disc. Install outer flange with flat side facing toward piston side. Install snap ring. Ensure
snap ring end-gap is not aligned with cutouts.
7. Check operation of 1st and reverse brake. Apply compressed air at oil passage of transaxle case to
confirm piston movement. See Fig. 15
. Check pack clearance of 1st and reverse brake. Clearance for A-
540E is .33-.081" (.85-2.05 mm). Clearance for A-540H is .041-.085" (1.04-2.16 mm). Clearance for A-
541E is .076-.106" (1.92-2.86 mm). See Fig. 68
.
8. Install No. 2 one-way clutch in case. Install one-way clutch while turning planetary gear clockwise with
snap ring expander. Check operation of No. 2 one-way clutch by turning planetary gear. Gear should turn
freely clockwise and lock counterclockwise. See Fig. 69
. Install snap ring. Ensure end gap is not aligned
with cutouts.
9. Install thrust washer on rear planetary gear. Install 2nd coast brake band guide with correct bolt. Place
thrust washer on No. 1 one-way clutch. Install No. 1 one-way clutch into rear planetary gear.
10. Install 2nd brake flange with flat end facing up. Install 2nd brake discs and plates, starting with disc and
ending with plate. Place piston return spring in case. Place 2nd brake drum in case. Ensure groove of
drum is aligned with bolt. While compressing piston return springs over drum with hammer handles,
install snap ring in groove. Ensure snap ring end gap is not aligned with cutouts.
11. Install NEW 2nd brake gasket until contact is made with 2nd brake drum. See Fig. 14
. Check operation
of 2nd brake by applying compressed air into oil passage. Make sure the piston moves freely. See Fig.
13 .
12. Install thrust washer on sun gear input drum (shell). Install sun gear by turning clockwise and installing in
No. 1 one-way clutch. Install oil seal ring to intermediate shaft. Install front planetary gear with bearing
on both sides of gear on sun gear. Install front planetary ring gear onto sun gear.
13. Install 2nd coast brake band into case. Install pin through oil pump mounting bolt hole. Install thrust
bearings on both sides of forward clutch. Install thrust washer with oil groove facing upward onto direct
clutch drum.
14. Mesh hub of forward clutch with flukes of direct clutch discs. Ensure bearing and thrust washer do not
move out of place. Install direct and forward clutch into case. Hold direct clutch toward forward clutch to
prevent thrust washer from moving out of place. Check distance between direct clutch drum and sun gear
input drum. See Fig. 70
. Distance should be .12" (3 mm). NOTE: For thrust bearing and race location and identification, see Fig. 73
and Fig.
74 .

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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Tuesday, August 18, 2009 7:18:46 PMPage 2 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Tuesday, August 18, 2009 7:18:46 PMPage 3 © 2005 Mitchell Repair Information Company, LLC.

step 2). If throttle valve is not fully open, adjust throttle linkage or cable so throttle valve is fully open and
then go to step 2).
2. Ensure accelerator pedal is fully depressed. Loosen adjusting nuts on throttle valve cable. Adjust outer
cable so distance between end of rubber boot and stopper on throttle valve cable is 0-.04" (0-1.0 mm). See
Fig. 6
. Tighten adjusting nuts. Recheck distance once adjusting nuts are tightened.
Fig. 6: Measuring Distance On Throttle Valve Cable (Corolla 1.6L 4A
-FE, Pickup, Previa Non-
Supercharged, Tacoma 2WD 2.4L 4-Cyl., Tercel & 1995 4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
GEARSHIFT LINKAGE
Land Cruiser
1. Apply parking brake. Loosen control rod nut on control rod at control shaft lever on side of transmission.
See Fig. 7
. Rotate control shaft lever fully counterclockwise toward rear of vehicle to the Park position.
2. Rotate control shaft lever clockwise 2 notches to Neutral position. Ensure gearshift is in Neutral. While
holding control shaft lever lightly counterclockwise back toward the Reverse position, tighten control rod
nut.
3. Start engine. Ensure vehicle moves forward when shifting gearshift from Neutral to Drive, and in reverse
when shiftin
g to Reverse.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Tuesday, August 18, 2009 7:18:46 PMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 7: Adjusting Shift Linkage (Land Cruiser)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Pickup 2WD & Pickup 4WD With 2.4L 4-Cyl.
1. Apply parking brake. On models with column shift, remove control rod nut from control rod at bottom of
steering column. See Fig. 8
. Push control rod fully downward to the Park position.
2. Pull control rod upward 2 notches to the Neutral position. While holding gearshift lightly toward the
Reverse position, tighten control rod nut.
3. On models with floor shift, loosen nut for control rod at the gearshift. See Fig. 9
. Pull control rod fully
backward toward rear of vehicle to the Park position. Push control rod forward 2 notches to the Neutral
position. Ensure gearshift is in Neutral. Tighten nut for control rod at gearshift.
4. On all models, start engine. Ensure vehicle moves forward when shifting gearshift from Neutral to Drive,
and in reverse when shifting to Reverse.
Pickup 4WD With 3.0L V6 & 1995 4Runner 4WD With 3.0L V6
1. Apply parking brake. Loosen nut(s) for control rod at shift lever on driver's side of transmission. The
control rod fits between shifting mechanism at rear of the transmission and the shift lever on side of
transmission. The shifting mechanism has a rod which goes to the gearshift.
2. Pull control rod fully backward toward rear of vehicle to the Park position. Push control rod forward 2
notches to the Neutral position.
3. Ensure gearshift is in Neutral. While holding gearshift lightly toward the Reverse position, tighten nut(s)
for control rod. Supra, Tacoma With Floor Shift, 1995 4Runner 2WD & 4WD 2.4L 4-C
yl., & 1996

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Tuesday, August 18, 2009 7:18:46 PMPage 14 © 2005 Mitchell Repair Information Company, LLC.

4Runner
4. Apply parking brake. Loosen nut for control rod at the gearshift. See Fig. 9
. Pull control rod fully
backward toward rear of vehicle to the Park position.
5. Push control rod forward 2 notches to the Neutral position. Ensure gearshift is in Neutral. Tighten nut for
control rod at gearshift.
6. Start engine. Ensure vehicle moves forward when shifting gearshift from Neutral to Drive, and in reverse
when shifting to Reverse.
T100
1. Apply parking brake. Remove control rod nut from control rod at bottom of steering column. See Fig. 8 .
Push control rod fully downward to the Park position.
2. Pull control rod upward 2 notches to the Neutral position. While holding gearshift lightly toward the
Reverse position, tighten control rod nut.
3. Start engine. Ensure vehicle moves forward when shifting gearshift from Neutral to Drive, and in reverse
when shifting to Reverse.
Fig. 8: Adjusting Typical Shift Linkage For Column Shifts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
Microsoft
Tuesday, August 18, 2009 7:18:46 PMPage 15 © 2005 Mitchell Repair Information Company, LLC.