remove transaxle TOYOTA RAV4 1996 Service Service Manual

D02267
Magnet1
2
DI−208
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
2 Check front speed sensor.
PREPARATION:
Remove the front speed sensor from the transaxle.
CHECK:
Measure the resistance between terminals 1 and 2 of the speed
sensor.
OK:
Resistance: 560 − 680 Ω
Reference:
Check the front transaxle revolution sensor’s function
CHECK:
Check the voltage between terminals 1 and 2 of the speed sen-
sor when a magnet is put close to the front end of the front
speed sensor then taken away quickly.
OK:
Voltage is generated intermittently.
HINT:
The generated voltage is extremely low.
NG Replace front speed sensor.
OK
Check and repair harness and connector be-
tween ECM and front speed sensor.

D02269
RR+RR−
D02267
12
Magnet
DI−210
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check resistance between terminals RR+ and RR− of ECM.
CHECK:
Check the resistance between terminals RR+ and RR− of the
ECM.
OK:
Resistance: 560 − 680 Ω
OK Check and replace ECM.
NG
2 Check rear speed sensor.
PREPARATION:
Remove the rear speed sensor from transaxle.
CHECK:
Measure the resistance between terminals 1 and 2 of the revo-
lution sensor.
OK:
Resistance: 560 − 680 Ω
Reference:
Check the vehicle speed sensor’s function
CHECK:
Check the voltage between terminals 1 and 2 of the speed sen-
sor when a magnet is put close to the front end of the rear speed
sensor then taken away quickly.
OK:
Voltage is generated intermittently.
HINT:
The generated voltage is extremely low.
NG Replace rear speed sensor.
OK

D02274
(+)
(−)
DI−214
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
3 Check shift solenoid valve ST.
PREPARATION:
(a) Jack−up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the shift solenoid valve ST connector.
(d) Remove the shift solenoid valve ST.
CHECK:
Measure the resistance between solenoid connector and sole-
noid body.
OK:
Resistance: 11 − 15 Ω
CHECK:
Connect positive  lead to terminal of the solenoid connector,
negative  lead to the solenoid body.
OK:
The shift solenoid valve ST makes operations noise.
NG Replace shift solenoid valve ST.
OK
Check and replace or repair solenoid wire.

D02276
S1 3
S1 1Shift Solenoid
Valve SLD
BR−B
IG214 IG213
L−B
L−B
E6
E62
SLD−
SLD+
B+ ECM
BR−B3
D02277
2
1
2
1
DI−216
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check shift solenoid valve SLD.
Check solenoid resistance:
PREPARATION:
(a) Jack up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the connector.
CHECK:
Measure the resistance between terminals 1 and 2 of the sole-
noid connector.
OK:
Resistance: 5.1 − 5.5 Ω
Check solenoid operation:
CHECK:
Connect positive  lead with an 8 − 10 W bulb to terminal 1 of
the solenoid connector and nagative  lead to terminal 2, then
check the movement of the valve.
OK:
When battery positive voltage is appliedValve moves in → direction in illumina-
tion (on the left)
When battery positive voltage is cut offValve moves in ← direction in illumina-
tion (on the right)

D02310
3
1
54 2
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−231
1996 RAV4 (RM447U)
3 Check pattern select switch.
PREPARATION:
Remove the pattern select switch.
CHECK:
Measure the resistance between terminals 1 and 3 of the pat-
tern select switch connector when the select switch is set to
PWR and NORM positions.
OK:
PatternResistance
PWR0 Ω (continuity)
NORM∞ Ω (open)
NG Replace pattern select switch.
OK
4 Check harness and connector between battery and pattern select switch, and
pattern select switch and ECM (See page IN−30).
NG Repair or replace harness or connector.
OK
Check and replace ECM.

BE3840N14700I09120
ON
OD (−)
(+)
DI−358
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check operation of overdrive.
PREPARATION:
Test drive after engine warm up.
CHECK:
Check that overdrive ON ↔ OFF occurs with operation of OD switch ON − OFF.
NG Check and repair electronically controlled
transaxle (See page DI−141 or DI−192).
OK
2 Check voltage between terminal OD of harness side connector of ECU and body
ground.
PREPARATION:
Remove ECU with connector still connected.
CHECK:
(a) Disconnect ECU connector.
(b) Turn ignition switch ON.
(c) Measure voltage between terminal OD of harness side
connector of ECU and body ground.
OK:
Voltage: 10 − 16 V
NG Go to step 5.
OK

EM1BA−02
S01374
Cover
Connector EM−68
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. REMOVE AIR CLEANER CAP AND CASE
8. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY, CABLE BRACKET AND CLAMPS
9. DISCONNECT ENGINE WIRE FROM RELAY BLOCK
NO. 2
(a) Remove the 2 bolts, and disconnect the relay block No.
2 from the body.
(b) Remove the upper cover.
(c) Disconnect the connector.
(d) Remove the 2 nuts and disconnect the engine wire.
10. REMOVE CHARCOAL CANISTER
11. REMOVE GENERATOR (See page CH−7)
12. REMOVE RADIATOR UPPER AND LOWER HOSES
13. REMOVE WATER INLET
Remove the 2 nuts and water inlet.
14. DISCONNECT HEATER HOSES
15. DISCONNECT FUEL INLET HOSE
CAUTION:
Catch leaking fuel in a container.
16. M/T only:
REMOVE STARTER (See page ST−4)
17. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable on the trans-
axle.

S01351
Buck−up Light
Connector M/T only
S01797
M/T
A/T
S01785
A/T only
− ENGINE MECHANICALENGINE UNIT
EM−69
1996 RAV4 (RM447U)
18. M/T only:
DISCONNECT CLUTCH RELEASE CYLINDER FROM
TRANSAXLE
(a) Disconnect the back−up light switch connector.
(b) Remove the clamp, and disconnect the tube from the
bracket.
(c) Remove the bolt, and disconnect the bracket from the
transaxle.
(d) Remove the clamp bolt, and disconnect the tube from the
transaxle.
(e) Remove the 2 bolts, and disconnect the release cylinder
from the transaxle.
19. DISCONNECT TRANSAXLE CONTROL CABLE(S)
FROM TRANSAXLE
20. A/T only:
DISCONNECT TRANSAXLE CONTROL CABLE FROM
FRONT SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
Remove the 2 bolts, and disconnect the control cable from the
crossmember and center member.
21. A/T and 4WD w/ M/T:
DISCONNECT TRANSAXLE OIL COOLER HOSES

R10966
S01357
Engine
Hanger
No. 1
S01296
S01350
S01559
Ground Strap
Connector EM−72
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
(e) Remove the 3 bolts, and disconnect the PS pump from
the engine.
HINT:
Suspend the PS pump securely.
32. REMOVE ENGINE AND TRANSAXLE ASSEMBLY
FROM VEHICLE
(a) Install a engine hange No. 1 in the correct direction.
Part No. 1:
Engine hanger No. 1 12281−74060
Bolt 91611−B1020
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Attach the engine sling device to the engine hangers.
(c) Remove the 2 nuts and 2 bolts, and disconnect the LH en-
gine mounting bracket from the mounting insulator.
(d) Disconnect the ground strap connector.
(e) Remove the bolt and 2 nuts, and disconnect the RH en-
gine mounting bracket from the mounting insulator.

S01326
− ENGINE MECHANICALENGINE UNIT
EM−73
1996 RAV4 (RM447U)
(f) Lower the engine out of the vehicle slowly and carefully,
and raise the vehicle.
HINT:
Make sure the engine is clear of all wiring, hoses and cables.
(g) Place the engine and transaxle assembly onto the stand.
33. 2WD:
REMOVE DRIVE SHAFT BEARING BRACKET
34. SEPARATE ENGINE AND TRANSAXLE
(M/T (2WD): See page MX−3)
(M/T (4WD): See page MX−9)
(A/T/A241E (2WD): See page AX−15)
(A/T/A540H (2WD): See page AX−19)
35. M/T only:
REMOVE CLUTCH COVER AND DISC