TOYOTA RAV4 1996 Service Owner's Manual

− AUTOMATIC TRANSAXLE (A241E)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX−21
1996 RAV4 (RM447U)
HINT:
Mark the position of the torque converter clutch to ensure cor-
rect installation.

AX04K−02
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE SYSTEM
AX−1
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE SYSTEM
PRECAUTION
When working with FIPG material, you must observe the followings.
Using a razor blade and a gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section.

AX04L−01
D00690
Planetary Gear Unit
O/D Direct
Clutch (C
0)O/D Brake (B0)1st & Reverse
Brake (B
3)
One−Way Clutch
No.2 (F
2)2nd Brake (B
2)
Forward
Clutch (C
1)2nd Coast
Brake (B
1)
Direct Clutch (C
2)
Input Shaft Front Planetary
Gear
One−Way Clutch
No.1 (F
1) Rear Planetary
Gear
Intermediate
Shaft Counter
Drive Gear
O/D Planetary
Gear O/D One−Way
Clutch (F
0)
Shift Lever
PositionGear Position
C
0C1C2B0B1B2B3F0F1F2
P Parking
Reverse
Neutral
1st
2nd
3rd
O/D R
N
D
2
L1st
2nd
*3rd
1st
*2nd








































*Down−shift only − no up−shift
 : Operating AX−2
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE SYSTEM
1996 RAV4 (RM447U)
OPERATION

Q06043
SST
AX04M−02
Q06044
SST
− AUTOMATIC TRANSAXLE (A540H)EXTENSION HOUSING OIL SEAL
AX−3
1996 RAV4 (RM447U)
EXTENSION HOUSING OIL SEAL
ON−VEHICLE REPAIR
1. DRAIN TRANSFER OIL
2. REMOVE PROPELLER SHAFT
(See page PR−3)
3. REMOVE EXTENSION HOUSING OIL SEAL
Using SST, remove the oil seal.
SST 09308−00010
4. INSTALL EXTENSION HOUSING OIL SEAL
(a) Using SST and a hammer, driver in a new oil seal.
SST 09325−20010
Oil seal depth: 1.5 ± 0.4 mm (0.059 ± 0.016 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL PROPELLER SHAFT
(See page PR−9)
6. FILL TRANSFER WITH OIL
(See page DI−173)

Q08739
AX04N−01
Q06120
Vehicle Speed
SensorO−Ring
Clip Driven Gear
Q08737
Q06119O−Ring
AX−4
− AUTOMATIC TRANSAXLE (A540H)VEHICLE SPEED SENSOR
1996 RAV4 (RM447U)
VEHICLE SPEED SENSOR
ON−VEHICLE REPAIR
1. REMOVE FRONT SPEED SENSOR
(a) Remove the air cleaner assembly.
(b) Disconnect the front speed sensor connector.
(c) Remove the bolt and front speed sensor assembly.
(d) Remove the clip and speedometer driven gear from the
front speed sensor.
(e) Remove the O−ring from the front speed sensor.
2. INSTALL FRONT SPEED SENSOR ASSEMBLY
(a) Coat a new O−ring with ATF and install it to the front
speed sensor.
(b) Install the speedometer driven gear to the front speed
sensor with the clip.
(c) Install the front speed sensor assembly with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Connect the front speed sensor connector.
(e) Install the air cleaner assembly.
3. REAR SPEED SENSOR
(a) Remove the air cleaner assembly.
(b) Disconnect the rear speed sensor connector.
(c) Remove the bolt and rear speed sensor.
(d) Remove the O−ring from the rear speed sensor.
4. INSTALL REAR SPEED SENSOR
(a) Coat a new O−ring with ATF and install it to the rear speed
sensor.
(b) Install the rear speed sensor with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(c) Connect the rear speed sensor connector.
(d) Install the air cleaner assembly.

Q08865
AX04O−01
− AUTOMATIC TRANSAXLE (A540H)ATF TEMPERATURE SWITCH
AX−5
1996 RAV4 (RM447U)
ATF TEMPERATURE SWITCH
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. REMOVE ATF TEMPERATURE SWITCH
(a) Disconnect the ATF temperature switch connector.
(b) Remove the ATF temperature switch.
3. INSTALL ATF TEMPERATURE SWITCH
(a) Install the ATF temperature switch.
(b) Connect the ATF temperature switch connector.
4. INSTALL NO.2 ENGINE UNDER COVER

Q08738
AX128−01
Q06066
Q06109
Q06077NRP AX−6
− AUTOMATIC TRANSAXLE (A540H)PARK/NEUTRAL POSITION (PNP) SWITCH
1996 RAV4 (RM447U)
PARK/NEUTRAL POSITION (PNP)
SWITCH
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
3. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Remove the nut and disconnect the shift control cable.
(b) Remove the nut and shift control lever.
(c) Using a screwdriver, pry off the lock plate.
(d) Remove the nut and lock plate.
(e) Remove the 2 bolts and pull out the park/neutral position
switch.
4. INSTALL AND ADJUST PARK/NEUTRAL POSITION
SWITCH
(a) Install the park/neutral position switch to the manual valve
shaft with the 2 bolts and nut.
(b) Install a new lock plate and tighten the nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)
(c) Stake the nut with the lock plate.
(d) Temporarily install the manual valve lever shaft.
(e) Turn the lever counterclockwise until it stops, then turn it
clockwise 2 notches.
(f) Remove the shaft control lever.

Q06078
Neutral
Basic
Line
Groove
Q08738
− AUTOMATIC TRANSAXLE (A540H)PARK/NEUTRAL POSITION (PNP) SWITCH
AX−7
1996 RAV4 (RM447U)
(g) Adjust the park/neutral position switch
(See page AX−6).
HINT:
Align the groove and park/neutral basic line
(h) Tighten the 2 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(i) Install the shaft control lever with the nut.
Torque: 12.7 N·m (130 kgf·cm, 9 ft·lbf)
(j) Connect the control cable with the nut.
5. CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
6. INSTALL NO.2 ENGINE UNDER COVER

Q06064
AX129−01
AT0103
D00691
D00692
AX−8
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DRAIN ATF
Using a 10 mm hexagon wrench, remove the drain plug, and
drain the ATF into a suitable container.
3. REMOVE OIL PAN AND GASKET
(a) Remove the 17 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE:
Some fluid remain in the oil pan.
4. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Lock carefully at the chips and particles in the oil pan and on the
magnet to anticipate when type of wear you will find in the trans-
axle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bushing wear
5. REMOVE OIL PIPE BRACKET AND STRAINER
(a) Remove the 2 bolts and oil pipe bracket.
(b) Remove the 3 bolts and strainer.
(c) Remove the gasket from the strainer.
6. REMOVE MANUAL VALVE BODY
(a) Remove the 2 bolts and detent spring.

D00693
Q05896
Q05897
D00645
Q05899
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−9
1996 RAV4 (RM447U)
(b) Remove the 5 bolts and manual valve body with the
manual valve.
(c) Remove the manual valve from the manual valve body.
7. REMOVE OIL PIPE
(a) Remove the bolt and retainer.
(b) Pry up both pipe ends with a large screwdriver and re-
move the 8 pipes.
NOTICE:
Be careful not to bend or damage the pipes.
8. DISCONNECT 3 SOLENOID CONNECTORS
9. REMOVE CONNECTOR CLAMP AND PIPE RETAINER
10. REMOVE B
3 APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.
NOTICE:
Be careful not to bend or damage the pipes.