TOYOTA RAV4 1996 Service User Guide

AX04X−02
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
AX−11
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX0T7−02
Z19320
STPSLS
+
P2
IG
ACC
KLS
+EP1
P
SLS−
Wire Harness Side ABC
AT5027
AT5029
Battery AX−12
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
ConnectorTerminalMeasuring conditionVoltage (V)
A
5 − 4 (ACC − E)Ignition switch ACC10 − 14
1 − 4 (IG − E)Ignition switch ON10 − 14
2 − 4 (STP − E)Depress brake pedal10 − 14
6 − 4 (KLS+ − E)
2. Ignition switch ACC and P position0
3. Ignition switch ACC and except P position7.5 − 11
4. (After−approx. 1 second)5.5 − 10
B1 − 2 (SLS+ − SLS−)
1. Ignition switch ON and P position0
2. Depress brake pedal8.5 − 14
3. Except P position0
C
1 − 2 (P1 − P)1. Ignition switch ON, P position and depress brake pedal0
2. Shift except P position under condition above10 − 14
3 − 2 (P2 − P)1. Ignition switch ACC and P position10 − 14
2. Shift except P position under condition above0
2. INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 26 − 33 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If solenoid operation is not as specified, replace the solenoid.

Q09052
21
Q09053
21
Z193392 (P)1 (P2)
3 (P1)
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
AX−13
1996 RAV4 (RM447U)
3. INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 12.5 − 16.5 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If solenoid operation is not as specified, replace the solenoid.
4. INSPECT SHIFT LOCK CONTROL SWITCH
Inspect that there is continuity between each terminal.
Shift positionTester connectionSpecified value
P position (Release button
is not pushed)2 − 3 (P − P1)Continuity
P position (Release button
is pushed)2 − 3 (P − P1)
2 − 1 (P − P2)Continuity
R, N, D, 2, L position2 − 1 (P − P2)Continuity
If continuity is not as specified, replace the switch.

AX0T8−01
Z18886
RH Drive Shaft
LH Drive Shaft  Snap Ring
64 (650, 47)
 Cotter Pin
Lock Cap
216 (2,200, 159)
 Gasket
49 (500, 36)
7.0 (75, 65 in.·lbf)
62 (630, 46)
48 (490, 35)
Front Exhaust PipeEngine Mounting
Center MemberPS Gear Assembly
Front Suspension Crossmember
Assembly with Stabilizer Bar
RH Engine Under Cover
LH Engine Under Cover
137 (1,400, 101)
206 (2,100, 152)
127 (1,300, 94)
72 (730, 53)

73 (740, 54)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
113 (1,150 83)
 Cotter Pin
 Gasket
35 (360, 26)
64 (650, 47)
64 (650, 47)
19 (194, 14)
25 (250, 18)
46 (470, 34)
27 (280, 20)
25 (250, 18)
9.0 (95, 78 in.·lbf)
64 (650, 47)
9.0 (95, 78 in.·lbf)
37 (380, 27)
13 (135, 10)
39 (400, 29)64 (650, 47)
 GasketStarterEngine Wire
Clamp Plug for Line
Pressure Test
Shift Control
Cable ClipRear End Plate Stiffener Platex 6 Torque Converter
ClutchEngine Coolant Reservoir TankABS RelayAir Intake Connector
Air Cleaner
Case Assembly AX−14
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

D02186
AX127−01
Q08747
Q08761
D02187
Q08763
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT THROTTLE CABLE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the connector and ABS relay.
(b) Remove the 3 bolts and air cleaner assembly.
4. REMOVE GROUND CABLE
Remove the bolt from the transaxle.
Torque: 19 N·m (194 kgf·cm, 14 ft·lbf)
5. REMOVE SET NUT OF ENGINE WIRE CLAMP
6. REMOVE STARTER
(a) Disconnect the connector and nut from the starter.
(b) Remove the 2 bolts and disconnect the engine wire.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Remove the starter.
7. REMOVE 3 UPPER SIDE TRANSAXLE MOUNTING
BOLTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
8. INSTALL ENGINE SUPPORT FIXTURE

Q08764
Q08765
Q08766
Q08767
AX−16
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
9. REMOVE ENGINE LEFT MOUNTING BOLT AND NUTS
Torque:
Bolt: 64 N·m (650 kgf·cm, 47 ft·lbf)
Nut: 64 N·m (650 kgf·cm, 47 ft·lbf)
10. REMOVE LEFT AND RIGHT ENGINE UNDER COVERS
11. DRAIN ATF
12. REMOVE LEFT AND RIGHT DRIVE SHAFTS
(See page SA−20)
13. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts and gasket from the exhaust pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Replace used gasket with new gasket.
(b) Remove the 3 nuts, front exhaust pipe and gasket.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Replace used nuts and gasket with new nuts and gasket.
14. DISCONNECT SHIFT CONTROL CABLE
(a) Remove the nut from the control shaft lever.
Torque: 13 N·m (135 kgf·cm, 10 ft·lbf)
(b) Remove the clip and disconnect the control cable.
(c) Remove the 2 shift cable mounting bolts.
Torque: 7.0 N·m (75 kgf·cm, 65 in.·lbf)

Q08774
Q08768
D01757
Q08769
C
D
NutAB C
D
A
B
B
B
Nut
Q08770
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−17
1996 RAV4 (RM447U)
15. DISCONNECT FOLLOWING CONNECTORS
Shift solenoid valve SL connector
Park/neutral position switch connector
Vehicle speed sensor connector
16. DISCONNECT 2 OIL COOLER HOSES
Loosen the 2 clips and disconnect the 2 oil cooler hoses.
17. REMOVE 2 POWER STEERING GEAR MOUNTING
BOLTS AND NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
NOTICE:
Support the power steering gear housing securely.
18. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
Remove the 10 bolts, 2 nuts and front suspension crossmem-
ber assembly with stabilizer bar.
Torque:
A bolt: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
B bolt: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
C bolt: 35 N·m (360 kgf·cm, 26 ft·lbf)
D bolt: 72 N·m (730 kgf·cm, 53 ft·lbf)
Nut: 73 N·m (740 kgf·cm, 54 ft·lbf)
19. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

Z18887
A
A
A
B
Q08772
Q08773
A
B AX−18
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
20. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
A bolt: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
B bolt: 19 N·m (195 kgf·cm, 14 ft·lbf)
21. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLT
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley set bolt by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
First install the gray bolt. Then install 5 black bolts while turning
the crankshaft to grain access.
22. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
23. REMOVE TRANSAXLE
Remove the rear side transaxle mouting 2 bolts and transaxle.
Torque:
A bolt: 25 N·m (250 kgf·cm, 18 ft·lbf)
B bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)

AT3412
AX059−03
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH
Using calipers and a straight edge, measure from the installed
surface to front surface of the transaxle housing.
Correct distance: More than 12.75 mm (0.502 in.)
2. INSTALL TRANSAXLE
Installation is in the reverse order of removal (See page
AX−15).
HINT:
After installation, check and inspect items as follows.
Fluid level (See page DI−127)
Front wheel alignment (See page SA−4)
Road test the vehicle

AT0953
SST
AX05A−02
AT3306
Hold
Lock
Free
Turn
D00776
AT4184
AX−20
− AUTOMATIC TRANSAXLE (A241E)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
1996 RAV4 (RM447U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST into the inner race of the one−way clutch.
SST 09350−32014 (09351−32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one−way clutch.
SST 09350−32014 (09351−32020)
(c) With the torque converter clutch standing on its side,the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter clutch and retest the clutch.
Replace the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or if the ring gear is
damaged, replace the drive plate. If installing a new drive plate,
note the orientation of spacers and tighten the bolts.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correcting by
reorienting the installation of the converter clutch.