TOYOTA RAV4 1996 Service Service Manual

Q08839
Q06112
Z17589
AX−20
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
7. REMOVE CENTER STIFFENER PLATE
Remove the 4 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE TRANSAXLE WITH TRANSFER ASSEMBLY
(a) Remove the 2 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 5 transaxle mounting bolts.
Torque:
14 mm head bolt: 64 N·m (650 kgf·cm, 47 ft·lbf)
12 mm head bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)
(c) Separate the transaxle assembly.

AT3412
AX04V−01
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
AX−21
1996 RAV4 (RM447U)
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using calipers and a straight edge, measure the distance from
the installed surface to front surface of the transaxle housing.
Correct distance: More than 13.7 mm (0.539 in.)
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal (See page
AX−19).
HINT:
After installation, check and inspect the following items.
Fluid level (See page DI−173)
Front wheel alignment (See page SA−4)
Do the road test

AT0952
SST
AX04W−01
AT0953
SST
AT3306
Hold
Lock
Free
Turn
AT2821
AX−22
− AUTOMATIC TRANSAXLE (A540H)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
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, or ring gear is dam-
aged replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

AT4184
− AUTOMATIC TRANSAXLE (A540H)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX−23
1996 RAV4 (RM447U)
3. MEASURE TORQUE CLUTCH CONVERTER SLEEVE
RUNOUT
(a) Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator and measure the torque con-
verter clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter clutch.
HINT:
Mark the position of the converter clutch to ensure correct
installation.
(b) Remove the torque converter clutch.

BE0J3−04
BE−10− BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCH
1996 RAV4 (RM447U)
IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH
LOCATION

N11771
1
82 3
4
65 7
BE0J4−04
Z10028
1
2
OFF
ON
N01923
N01924
N01925
− BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCHBE−11
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
LOCK−No continuity
ACC2 − 3Continuity
ON2 − 3 − 4, 6 − 7Continuity
START1−2−4, 6−7−8Continuity
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTI-
NUITY
Switch positionTester connectionSpecified condition
SW OFF
(Key removed) −No continuity
SW ON (Key set)1 − 2Continuity
If continuity is not as specified, replace the switch.
3. Key Unlock Warning System:
INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
A1.
(b) Connect the negative (−) lead from the battery to termi-
nals A5, A6 and A10.
(c) Check the buzzer sounds.
(d) Disconnect the negative (−) lead from the battery to termi-
nals A6.
(e) Check that the buzzer stops sounding.
(f) Connect the negative (−) lead from the battery to termi-
nals A6.
(g) Disconnect the negative (−) lead from the battery to termi-
nals A5.
(h) Check that the buzzer stops sounding.
If operation is not as specified, replace the relay.

BE−12− BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCH
1996 RAV4 (RM447U)
4. INSPECT INTEGRATION RELAY CIRCUIT (See page
BE−37)
5. INSPECT DOOR COURTESY SWITCH CONTINUITY
(See Page BE−22)

BE0J5−06
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−13
1996 RAV4 (RM447U)
HEADLIGHT AND TAILLIGHT SYSTEM
LOCATION

BE0J6−01
N17327
Light Control SwitchSwitch BodyWiper and Washer Switch
Spiral Cable BE−14
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
1996 RAV4 (RM447U)
COMPONENTS

BE1MW−01
Z17623
HEAD
TA I L
OFFRight
LeftFlash
8
7
17 16
1413
Z13558
3
4
21
3
4 2
1
Z05657
3 21 3
21
55
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−15
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT LIGHT CONTROL SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
OFF−No continuity
TAIL14 − 16Continuity
HEAD13 − 14 − 16Continuity
If continuity is not as specified, replace the switch.
2. INSPECT HEADLIGHT DIMMER SWITCH CONTINU-
ITY
Switch positionTester connectionSpecified condition
Flash7 − 8 − 16Continuity
Low beam16 − 17Continuity
High beam7 − 16Continuity
If continuity is not as specified, replace the switch.
3. INSPECT HEADLIGHT CONTROL RELAY CONTINU-
ITY
ConditionTester connectionSpecified condition
Constant3 − 4Continuity
Apply B+ between
terminals 3 and 4.1 − 2Continuity
If continuity is not as specified, replace the relay.
4. INSPECT TAILLIGHT CONTROL RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 − 2Continuity
Apply B+ between
terminals 1 and 2.3 − 5Continuity
If continuity is not as specified, replace the relay.
5. Light−on Warning System:
INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
1 and 12, the negative (−) lead to terminals 10.
(b) Check that the buzzer sounds when the negative (−) lead
from the battery is connected to terminal 6.
If operation is not as specified, replace the relay.
6. INSPECT DOOR COURTESY SWITCH CONTINU-
ITY(See pageBE−22)