shift TOYOTA RAV4 1996 Service Workshop Manual

Q05352
Cruise Control ECU
C16
ECM
4 − 6 V
9
ODOD1
Y−B20
E6
D02210
ON
OD1
DI−166
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
O/D Cancel Signal Circuit
CIRCUIT DESCRIPTION
While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruis-
ing, O/D may be prohibited temporarily under some conditions.
The cruise control ECU sends O/D cur signals to the ECM as necessary and the ECM cancels O/D shifting
until these signals are discontinued.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check voltage between terminal OD1 of ECM and body ground.
PREPARATION:
Turn the ignition switch ON.
CHECK:
Measure the voltage between terminal OD1 of the ECM and
body ground.
OK:
Voltage: 4 − 6 V
OK Proceed next circuit inspection shown on prob-
lem symptoms table (See page DI−141).
NG
DI40O−01

Q08867
Junction Connector
Fuse Block
FL Block
DI−168
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
Pattern Select Switch Circuit
CIRCUIT DESCRIPTION
The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, and L posi-
tion and the lock−up patterns. Following the programs corresponding to the signals from the pattern select
switch, the park/neutral position switch and other various sensors, the ECM switches the solenoid valves
ON and OFF, and control the transmission gear change and the lock−up clutch operation.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of PWR indicator light.
CHECK:
Check if the PWR indicator light normally when the pattern select switch is set to NORM and PWR position.
OK:
Pattern select switchPWR indicator light
PWRLight up
NORMGoes off
NG Check and repair PWR indicator light (See page
BE−2).
OK
DI40P−02

DI40R−02
Vehicle Brought to Workshop
Customer Problem Analysis
Check DTC and Freeze Frame Data (Pre−check)
Record or Print DTC and Freeze Frame Data P.
DI−173
Clear DTC and Freeze Frame Data P. DI−173
Visual Inspection
Setting the Check Mode Diagnosis P.
DI−173
1
Items insideare titles of pages in this manual, with the
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.

Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3.
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the
scan tool / TOYOTA hand−held tester, inspect DLC3 P.
DI−173
2
3
4
5
6
Symptom does not occur
Problem Symptom Confirmation8
7Symptom Simulation
P. I N−XXX
Symptom occurs
DTC CheckP. DI−173OK Code11Preliminary Check
P.
DI−173
DTC Chart
P. DI−189Mechanical System Test
P.
DI−173
Manual Shifting Test
P.
DI−173 OK
OK
Chapter 1
(Electronic)Chapter 2
(On−Vehicle)OKChapter 3
(Off−Vehicle)OK Matrix Chart of Problems Symptoms − P. DI−192
Circuit
Inspection O/D Cancel Signal Circuit Check
 Stop Light Signal Check
NG
Parts Inspection
NG
NGNG
Identification of ProblemRepairConfirmation TestEnd
NG
NG
13NG
15 16
17 18 9
10
P. DI−192
P. DI−196 − DI−229 P. DI−172
12
14
P. DI−192P. DI−192
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake−out−box.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−171
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE (A540H)
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following pages.

DI40S−01
Transaxle Control
System Check SheetInspector ’s
Name:
Customer ’s Name
Registration No.
Registration Year
Frame No.
Date Vehicle
Brought InOdometer Readingkm
mile / /
/ /
Date Problem
Occurred
Frequency Prob-
lem Occurs?/ /
 Continuous  Intermittent ( times a day)
Symptoms
 Vehicle does not move (  Any position  Particular position )
 No up−shift (  1st → 2nd  2nd → 3rd  3rd → O/D )
 No down−shift (  O/D → 3rd  3rd → 2nd  2nd → 1st )
 Lock−up malfunction
 Shift point too high or too low
 Harsh engagement (  N → D  Lock−up  Any drive position )
 Slip or shudder
 No kick−down
 Others
Check ItemMalfunction
Indicator Lamp
DTC Check
1st Time
2nd Time Normal code  Malfunction code (Code )  Normal Remains ON
 Normal code  Malfunction code (Code ) DI−172
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−177
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 a simulation test (See page IN−30).
(4) Check the connector connection and terminal (See page IN−30).
(5) Visual check and contact pressure (See page IN−30).
(6) Handle the connector (See page IN−30).
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, does 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
symptoms.
6. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test in NORM and PWR pattern ranges.
Shift into the D position and hold the accelerator pedal constant at the full throttle valve opening posi-
tion and check the following:
(1) 1 → 2, 2 → 3 and 3 → O/D up−shift should take place, and shift points should conform to those
shown in the automatic shift schedule (See page SS−34).
HINT:
There is not O/D up−shift and lock−up when the engine coolant temperature is below 60°C (140°F).
There is not lock−up when the vehicle speed is 10 km/h (6 mph) less than the set cruise control speed.
ProblemPossible cause
If there is no 1 → 2 up−shiftShift solenoid valve No. 2 stuck
1−2 shift valve is stuck
If there is no 2 → 3 up−shiftShift solenoid valve No. 1 is stuck
2−3 shift valve is stuck
If there is no 3 → O/D up−shift3−4 shift valve is stuck
If the shift point is defectiveThrottle valve, 1−2 shift valve, 2−3 shift valve, 3−4 shift valve etc., are defective
If the lock−up is defectiveShift solenoid valve SL is stuck
Lock−up relay valve is stuck
(2) In the same way, check the shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
Evaluation:
ProblemPossible cause
If the shock is excessive
Line pressure is too high
Accumulator is defective
Check ball is defective
(3) Run at the D position lock−up or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of any abnormal noise and vibration must be made with extreme care as it could
also be due to loss of balance in the drive shaft, tire, torque converter clutch, etc.
(4) While running the D position, 2nd, 3rd and O/D gears, check to see that the possible kick−down
vehicle 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−34).
(5) Check for abnormal shock and slip at kick−down.

DI−178
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(6) Check for 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 engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test.
Shift into the 2 position and, while driving with the accelerator pedal held constantly at the full throttle
valve opening position, push in one of the pattern selectors and check on the following points.
(1) Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to that shown
on the automatic shift schedule (See page SS−35).
(2) While running in the 2 points and 2nd gear, release the accelerator pedal and check the engine
braking effect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect2nd coast brake is defective
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
(1) While running in the L position, check to see that there in no up−shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect1st and reverse brake defective
(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 an 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 to see that the parking lock pawl holds the vehicle in place.

Q06070
D02315
OK if hot
Add if hot
D00697
Ok if hot
Add if hot
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−179
1996 RAV4 (RM447U)
7. BASIC INSPECTION
(a) Check the ATF level.
HINT:
The vehicle must have been driven so that the engine and
transaxle are at normal operating temperature.
ATF temperature: 70 − 80°C (158 − 176°F)
(1) Park the vehicle on a level surface, set the parking
brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into each gear from the
P position to L position smoothly and return to the
P position.
(3) Pull out the transaxle dipstick 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 of the hot range, add fluid.
Fluid type: ATF type T or equivalent
NOTICE:
Do not overfill.
(b) Check the transfer oil level.
(1) Park the vehicle on a level surface, set the parking
brake.
(2) Pull out the transfer dipstick and wipe it clean.
(3) Push it back fully into the pipe.
(4) Pull it out and check the oil level, as shown in the il-
lustration.
Oil grade: API GL−5
Oil viscosity: SAE 75W−90

Q06065
Q06076
D02315
OK if hot
Add if hot
D00699
D00700
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−181
1996 RAV4 (RM447U)
(d) Replace the ATF.
NOTICE:
Do not overfill.
(1) Using a 10 mm hexagon wrench, remove the drain
plug, gasket and drain the fluid.
(2) Install a new gasket and the drain plug securely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF type T or equivalent
Drain and refill: 3.3 liters (3.5 US qts, 2.9 lmp. qts)
(4) Start the engine and shift the selector into all the
positions from P through L and then shift into the P
position.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level with the normal fluid tempera-
ture 70 − 80°C (158 − 176°F) and add as neces-
sary.
NOTICE:
Do not overfill.
(e) Replace the transfer oil.
(1) Using a 10 mm hexagon wrench, remove the drain
plug and drain the oil.
(2) Install the drain plug.
(3) Add new oil through the filler pipe.
Recommended oil:
Oil grade API GL−5
Viscosity SAE 75W−90
Capacity: 0.7 liters (0.7 US qts, 0.6 lmp. qts)
(4) Check the oil level and add as necessary.
NOTICE:
Do not overfill.

D00697
Ok if hot
Add if hot
AT4252
0 − 1 mm
D02248
DI−182
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(f) Check the fluid leaks.
Check for leaks in the transmission and transfer.
If there are leaks, it is necessary to repair or replace O − rings,
FIPG’s, oil seals or other parts.
(g) Inspect and adjust the throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and stopper on the cable is as
standard.
Standard boot and cable stopper distance:
0 − 1 mm (0 − 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustments.
(h) Adjust the shift control cable.
(1) Loosen the nut on the lever.
(2) Push the manual lever fully toward the right side of
the vehicle.

Q06077NRP
Q06078
Neutral
Basic
Line
Groove
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−183
1996 RAV4 (RM447U)
(3) Return the lever 2 notches to the NEUTRAL posi-
tion.
(4) Set the shift lever in the N position.
(5) While holding the lever lightly toward the ”R” posi-
tion side, tighten the shift lever nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolts.
Torque: 5.4 N·m(55 kgf·cm,48 in·lbf)
(j) Inspect the idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
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 operating 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 always be 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) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,400 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,400 ± 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