TOYOTA RAV4 1996 Service Owner's Guide

D00694
OR0038
Z13387A B CDC
C
D00696
AX−10
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
11. REMOVE VALVE BODY
(a) Remove the 10 bolts.
(b) Disconnect the throttle cable from the cam and remove
the valve body.
12. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the cable
end into the slot.
(b) Raise up the valve body into place.
NOTICE:
Do not entangle the solenoid wire.
(c) Install and tighten the 10 bolts.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Hand−tighten the 10 bolts first, then torque with a torque
wrench.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 32 mm (1.26 in.)
Bolt C: 43 mm (1.69 in.)
Bolt D: 55 mm (2.17 in.)
13. INSTALL B
3 APPLY PIPE
NOTICE:
Be careful not to bend or damage the pipe.

Z13388
A
B
Q05897
Q05896
Z13389A B
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−11
1996 RAV4 (RM447U)
14. INSTALL CONNECTOR CLAMP AND PIPE RETAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 39 mm (1.54 in.)
Bolt B: 43 mm (1.69 in.)
15. CONNECT 3 SOLENOID CONNECTORS
16. INSTALL OIL PIPE
(a) Using a plastic hammer, install the 8 pipes into their posi-
tions.
NOTICE:
Be careful not to bend or damage the pipes.
(b) Install and tighten the bolt and retainer.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
17. INSTALL MANUAL VALVE BODY AND DETENT
SPRING
(a) Align the manual valve with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Hand−tighten the 5 bolts first. Then, tighten them with a
torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 37 mm (1.46 in.)

Z13390A B
Z13391
A
BA
B
Q06019
Q06064
AX−12
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
(d) Place the detent springs on the manual valve body and
hand−tighten the 2 bolts first.
Then, tighten them with a torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 14 mm (0.55 in.)
Bolt B: 37 mm (1.46 in.)
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
18. INSTALL PIPE BRACKET AND OIL STRAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 53 mm (2.09 in.)
19. INSTALL MAGNETS IN PLACE
NOTICE:
Make sure that the magnets do not interfere with the oil
pipes.
20. INSTALL OIL PAN WITH NEW GASKET
(a) Install a new gasket and oil pan.
(b) Install and tighten 17 bolts.
Torque: 7.9 N·m (80 kgf·cm, 70 in.·lbf)
21. FILL ATF AND CHECK FLUID LEVEL
(a) Using a 10 mm hexagon wrench, install a new gasket and
the drain plug.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Fill the ATF and check the fluid level (See page DI−173).
22. INSTALL NO.2 ENGINE UNDER COVER

Q06117
AX04R−02
Q06068
Q057310.8 − 1.5 mm (0.031 − 0.059 in.) 200 mm
(7.87 in.)
− AUTOMATIC TRANSAXLE (A540H)THROTTLE CABLE
AX−13
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM LINKAGE
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
3. REMOVE VALVE BODY
(See page AX−8)
4. REMOVE THROTTLE CABLE
(a) Remove the bolt and pull the cable out of the transaxle
case.
(b) Remove the O−ring from the throttle cable.
5. INSTALL THROTTLE CABLE INTO TRANSAXLE
CASE
If the throttle cable is new do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Install a new O−ring to the throttle cable.
(e) Make sure to push it in all the way.
(f) Install and torque the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
6. INSTALL VALVE BODY
(See page AX−8)
7. CONNECT THROTTLE CABLE TO LINKAGE
8. ADJUST THROTTLE CABLE
(See page DI−173)
9. INSTALL PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
10. TEST DRIVE VEHICLE

Q06041
SST
AX04S−01
Q06072
Q06040SST
Q06042
SST AX−14
− AUTOMATIC TRANSAXLE (A540H)SIDE GEAR SHAFT OIL SEAL
1996 RAV4 (RM447U)
SIDE GEAR SHAFT OIL SEAL
ON−VEHICLE REPAIR
1. REMOVE BOTH DRIVE SHAFTS
(See page SA−20)
2. REMOVE LH SIDE GEAR SHAFT OIL SEAL
Using SST, pull out the oil seal.
SST 09308−00010
3. REMOVE RH SIDE GEAR SHAFT OIL SEAL
Using a screwdriver, remove the oil seal.
4. INSTALL LH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, driver in a new oil seal.
SST 09608−32010, 09950−70010 (09951−07100)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL RH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09608−32010, 09950−70010 (09951−07100)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
6. INSTALL BOTH DRIVE SHAFTS (See page SA−31)
7. CHECK FLUID LEVEL (See page DI−173)

AX04X−03
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 (A540H)SHIFT LOCK SYSTEM
AX−15
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX0ZJ−02
Z19320
STPSLS
+
P2
IG
ACC
KLS
+EP1
P
SLS−
Wire Harness Side ABC
AT5027
AT5029
Battery AX−16
− AUTOMATIC TRANSAXLE (A540H)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
1 − 3 (ACC − E)IG SW ACC10 − 14
5 − 3 (IG − E)IG SW ON10 − 14
4 − 3 (STP − E)Depress brake pedal10 − 14
2 − 3
(KLS+ − E)
3. IG SW ACC and shift lever at P position0
4. Shift lever at R, N, D, 2, L position7.5 − 11
5. (after approx 1 second)5.5 − 10
B2 − 1
(SLS+ − SLS−)
1. IG SW ON and shift lever at P position0
2. Depress brake pedal8.5 − 14
3. Except P position0
C
3 − 2
(P1 − P)1. IG SW ON, shift lever at P position and depress brake
pedal0
2. Shift except P position under condition above10 − 14
1 − 2
(P2 − P)1. IG SW ACC and shift lever at 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 resistance between the ter-
minals.
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 the solenoid does not operated, replace the solenoid.

Q09052
21
Q09053
21
Z193392 (P)1 (P2)
3 (P1)
− AUTOMATIC TRANSAXLE (A540H)SHIFT LOCK SYSTEM
AX−17
1996 RAV4 (RM447U)
3. INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure resistance between the ter-
minals.
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 the solenoid does not operated, 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.

AX04T−01
Z19462
Center Stiffener
Plate
Plug for Line
Pressure Test
Starter Transaxle Plug for Center
Differential
Control Pressure
Test
Rear End Plate
Stiffener Plate
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
 Precoated part
37 (380, 27)
64 (650, 47)
46 (470, 34)
27 (280, 20)
9.3 (95, 82 in.·lbf)25 (250, 18)
39 (400, 29)
37 (380, 27)
9.3 (95, 82 in.·lbf)
37 (380, 27)46 (470, 34)
37 (380, 27)
64 (650, 47)
64 (650, 47) AX−18
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

Q06113
AX04U−02
Q05857
Z19463
Q05858
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See page
EM−68)
2. REMOVE STARTER
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
Bolt A: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
Bolt B: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley nut 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.
Coat the threads of the bolts with sealant.
Sealant: Part No. 08833 − 00070, THREE BONDS 1324
or equivalent
Tighten the bolts evenly.
First install dark green colored bolt and then the 5
bolts.
6. DISCONNECT CONNECTORS AND WIRE HARNESS
FROM TRANSAXLE