TOYOTA RAV4 1996 Service Repair Manual

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−131
1996 RAV4 (RM447U)
4. CHECK FOR INTERMITTENT PROBLEMS
TOYOTA hand−held tester only:
By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic
and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems.
(1) Clear the DTCs (See step 3).
(2) Set the check mode (See step 3).
(3) Do simulation test (See page IN−20).
(4) Check the connector connection and terminal (See page IN−30).
(5) Visual check and contact pressure (See page IN−20).
(6) Handle the connector (See page IN−20).
5. PROBLEM SYMPTOM CONFIRMATION
Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the
trouble. If the problem is that the transaxle does not up−shift, down−shift, or the shift point is too high or too
low, conduct the following road test to confirm the automatic shift schedule and simulate the problem symp-
toms.
6. ROAD TEST
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test.
Shift into the D position, keep the accelerator pedal constant at the full throttle valve opening position
and check the following points:
(1) Check up− shift operation.
Check that 1 → 2, 2 → 3 and 3 → O/D up−shift takes place, at the shift point shown in the automat-
ic shift schedule (See page SS−32).
HINT:
O/D Gear Up−shift Prohibition Control:
Engine coolant temperature is 50°C (122°F) or less.
If there is a 10km/h (6 mph) difference between the set cruise control speed and vehicle speed.
O/D main switch is pushed ON (During the O/D OFF indicator light lights up.).
O/D Gear Lock−up Prohibition Control:
Brake pedal is depressed.
Engine coolant temperature is 50°C (122°F) or less.
(2) Check for shift shock and slip.
Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
(3) Check for abnormal noise and vibration.
Run at the D position lock−up or O/D gear and check for abnormal noise and vibration.
HINT:
The check for the cause of abnormal noise and vibration must be performed very thoroughly as it could also
be due to loss of balance in the torque converter clutch, etc.
(4) Check kick−down operation.
While running in the D position, 2nd, 3rd and O/D gears, check that the possible kick−down ve-
hicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick−downs conform to those indicated on the
automatic shift schedule (See page SS−32).
(5) Check abnormal shock and slip at kick−down.
(6) Check the lock−up mechanism.
Drive in the D position, O/D gear, at a steady speed (lock−up ON) of about 75 km/h (47
mph).
Lightly depress the accelerator pedal and check that the RPM does not change abruptly.
If there is a big jump in RPM, there is no lock−up.

Q06070
AT3417
OK if hot
Add if hot DI−132
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
(b) 2 position test.
Shift into the 2 position and, while drive with the accelerator pedal held constantly at the full throttle
valve opening position, check on the following points:
(1) Check up−shift operation.
Check that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic shift
schedule (See page SS−32).
HINT:
There is no O/D up−shift and lock−up in the 2 position.
(2) Check engine braking.
While running in the 2nd gear of the 2 position, release the accelerator pedal and check the en-
gine braking effect.
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
Shift into the L position and while driving with the accelerator pedal held constantly at the full throttle
valve opening position, check the following points:
(1) Check no up−shift.
While running in the L position, check that there in no up−shift to 2nd gear.
(2) Check engine braking.
While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test.
Shift into the R position and while starting at full throttle, check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel and obstructions.
(e) P position test.
Stop the vehicle on a gradient (more than 5°) and after shifting into the P position, release the parking
brake. Then check that the parking lock pawl holds the vehicle in place.
7. BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transaxle are at
normal operating temperature.
Fluid temperature: 70 − 80°C (158 − 176°F)
Only use the COOL range on the dipstick as a rough refer-
ence when the fluid is replaced or the engine does not
run.
(1) Park the vehicle on a level surface and set the park-
ing brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into all positions from
the P to L position and return to the P position.
(3) Pull out the oil level gauge and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.
If the level is at the low side, add new fluid.

OR0028
Q06076
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−133
1996 RAV4 (RM447U)
Fluid type: ATF DEXRON ®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the fluid.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON ®II
Capacity:
Drain and refill: 3.3 liters (3.5 US qts, 2.9 lmp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 − 80°C (158 − 176°F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transaxle.
If there are leaks, it is necessary to replace O−rings, gaskets,
oil seals, plugs or other parts.
(e) Inspect and adjust throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not within the standard, adjust the cable by the
adjusting nuts.

Q08832
Q08831N
RP
Q07907
Neutral
Basic
Line
Groove
DI−134
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
(f) Inspect and adjust shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator correctly indicates the position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures:
(1) Loosen the nut on the control shaft lever.
(2) Push the control shaft lever fully downward.
(3) Return the control shaft lever 2 notches to the N
position.
(4) Set the shift lever to the N position.
(5) While holding the shift lever lightly toward the R
position side, tighten the shift lever nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in·lbf)
(6) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust park/neutral position switch.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.
If not as stated above, carry out the following adjustment proce-
dure:
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf)
HINT:
For continuity inspection of the park/neutral position switch, see
page DI−156.
(h) Inspect the idle speed.
Idle speed: 700 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall test
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operation ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should be always carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Fully apply the parking brake.
(3) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−135
1996 RAV4 (RM447U)
(4) Start the engine and check idle speed.
(5) Keep your left foot pressed firmly on the brake pedal.
(6) Shift into the D position. Fully depress the accelerator pedal. Quickly read the stall speed at this
time.
Stall speed: 2,370 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,370 ± 150 rpm
Evaluation:
ProblemPossible cause
Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT:
If more than 600 rpm below the specified value, the torque converter clutch could
be faulty
Stall speed high in D position
Line pressure too low
Forward clutch slipping
No. 2 one−way clutch not operating properly
U/D one−way clutch not operating properly
Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
U/D brake slipping
Stall speed high in D and R positions
Line pressure too low
Improper fluid level
U/D one−way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the U/D direct clutch, forward clutch,
direct clutch, and 1st and reverse brake.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Make sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Fully apply the parking brake
(2) Start the engine and check idle speed.
Idle speed: 700 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: N → D Less than 1.2 seconds
In the same way, measure the time lag for N → R.
Time lag: N → R Less than 1.5 seconds
Evaluation:
ProblemPossible cause
N → D time lag is longer
Line pressure too low
Forward clutch worn
U/D one−way clutch not operating properly
N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
U/D brake worn

DI−136
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
9. HYDRAULIC TEST
Measure the line pressure.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
The line pressure test should always carried out in pairs. One technician should observe the
conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the teat plug on the transaxle case left side and connect SST (See page AX−14. for the
location to connect SST).
SST SST 09992−00094 (09992−00230, 09992−00270)
(3) Chock the 4 wheels.
(4) Fully apply the parking brake.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressed firmly on the brake pedal and shift into the D position.
(7) Measure the line pressure when the engine is idling.
(8) Fully depress the accelerator pedal. Quickly read the highest line pressure when engine speed
reaches stall speed.
NOTICE:
Release the accelerator pedal and stop test if the wheels being to rotate before the engine speed
reaches specified stall speed.
(9) In the same way, do the teat in R position.
Specified line pressure:
ConditionD position kPa (kgf/cm2, psi)R position kPa (kgf/cm2, psi)
Idling353 − 422 (3.6 − 4.3, 51 − 61)598 − 804 (6.1 − 8.2, 87 − 117)
Stall824 − 971 (8.4 − 9.9, 119 − 141)1,530 − 1,780 (15.6 − 18.1, 222 − 257)
If the measured pressures are not up to specified values, recheck the throttle cable adjustment and do a
retest.
Evaluation:
ProblemPossible cause
If the measured value in all positions are higher.
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured values in all positions are lower.
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
U/D direct clutch defective
If pressure is low in the D position only.D position circuit fluid leakage
Forward clutch defective
If pressure is low in the R position only.
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective

Q08344
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−137
1996 RAV4 (RM447U)
10. MANUAL SHIFTING TEST
HINT:
With this test, it can be determined whether the trouble is within
the electrical circuit or is a mechanical problem in the transaxle.
(a) Disconnect the solenoid wire.
(b) Inspect the manual driving operation
Check that the shift and gear positions correspond with
the table below.
Shift PositionGear Position
DO/D
23rd
L1st
RReverse
PPawl Lock
HINT:
If the L, 2 and D position gear position are difficult to distinguish,
do the following road test.
While driving, shift through the L, 2 and D positions.
Check that the gear change corresponds to the shift posi-
tion.
If any abnormality is found in the above test, the problem
is in the transaxle itself.
(c) Connect the solenoid wire.
(d) Cancel out the DTC (See step 3).

DI40C−02
DI−138
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
DIAGNOSTIC TROUBLE CODE CHART
If a DTC is displayed during the DTC check, check the circuit listed in the table below and proceed to the
page given.
DTC No.
(See page)Detection ItemTrouble AreaMIL*Memory
P0500
(DI−94)Vehicle Speed Sensor
Malfunction
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM

P0750
(DI−146)Shift Solenoid A Malfunction
(Shift Solenoid Valve No. 1)Shift solenoid valve No. 1 is stuck open or closed
Valve body is blocked up or stuck
P0753
(DI−147)Shift Solenoid A Electrical
Malfunction
(Shift Solenoid Valve No. 1)Open or short in shift solenoid valve No. 1 circuit
Shift solenoid valve No. 1
ECM

P0755
(DI−146)Shift Solenoid B Malfunction
(Shift Solenoid Valve No. 2)Shift solenoid valve No. 2 is stuck open or closed
Valve body is blocked up or stuck
P0758
(DI−147)Shift Solenoid ”B” Electrical
Malfunction
(Shift Solenoid Valve No. 2)Open or short in shift solenoid valve No. 2 circuit
Shift solenoid valve No. 2
ECM

P0770
(DI−151)Shift Solenoid E Malfunction
(Shift Solenoid Valve SL)Shift solenoid valve SL is stuck open or closed
Valve body is blocked up or stuck
Lock−up clutch

P0773
(DI−153)Shift Solenoid E Electrical
Malfunction
(Shift Solenoid Valve SL)Open or short in shift solenoid valve SL circuit
Shift solenoid valve SL
ECM

P1780
(DI−156)Park/Neutral Position Switch
MalfunctionShort in park/neutral position switch circuit
Park/neutral position switch
ECM

*:  ...... MIL lights up

DI40D−02
Q08862
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−139
1996 RAV4 (RM447U)
PARTS LOCATION

DI40E−02
Z16062
ECM Terminals
E4E5
E6 DI−140
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
TERMINALS OF ECM
Symbols (Terminal No.)Wiring ColorConditionSTD Voltage (V)
SPD (E6−9) − E1 (E4−14)V−W − BRDisconnect cruise control connector and IG ON
Turn one front wheel slowlyPulse signal is output
Below 1 ↔ 4 − 6
S1 (E4−2) − E1 (E4−14)P−B − BR
IG OFF Disconnect ECM connector11 − 15 Ω
IG ON10 − 14
1st or 2nd gear10 − 14
3rd or O/D gearBelow 1
S2 (E4−15) − E1 (E4−14)P − BR
IG OFF Disconnect ECM connector11 − 15 Ω
IG ONBelow 1
2nd or 3rd gear10 − 14
1st or O/D gearBelow 1
SL (E4−1) − E1 (E4− 4)Y−B − BR
IG OFF Disconnect ECM connector11 − 15 Ω
IG ONBelow 1
Vehicle driving under look−up position10 − 14
OD1 (E6−20) − E1 (E4−14)Y−B − BRIG ON4 − 6
OD2 (E6−7) − E1 (E4−14)LG − BRO/D main switch ON (O/D ON)10 − 14
O/D main switch OFF (O/D OFF)Below 1
L (E6−19) − E1 (E4−14)LG − BRIG ON Shift lever L position10 − 14
IG ON Shift lever other than L positionBelow 1
R (E6−8) − E1 (E4−14)R−B − BRIG ON Shift lever R position10 − 14
IG ON Shift lever other than R positionBelow 1
2 (E−18)− E1 (E4−14)LG−R − BRIG ON Shift lever 2 position10 − 14
IG ON Shift lever other than R positionBelow 1
NSW (E6−22) − E1 (E4−14)B−W − BRIG ON Shift lever P or N positionBelow 1
IG ON Shift lever other than P or N position10 − 14
B/K (E6−4) − E1 (E4−14)G−W − BRIG ON Brake papel is depressed7.5 − 14
IG ON Brake papel is releasedBelow 1
P (E6−15) − E1 (E4−14)R−G − BRPWR pattern7.5 − 14
NORM patternBelow 1