differential TOYOTA RAV4 1996 Service Repair Manual

AX056−03
Z02840
SST
Z02841
SST LH Side
Z02842
SST
AX−10
− AUTOMATIC TRANSAXLE (A241E)DIFFERENTIAL OIL SEAL
1996 RAV4 (RM447U)
DIFFERENTIAL OIL SEAL
ON−VEHICLE REPAIR
1. DRAIN ATF
2. REMOVE ENGINE UNDER COVER
3. REMOVE LH AND RH DRIVE SHAFTS
(See page SA−20)
4. REMOVE LH AND RH SIDE OIL SEALS
Using SST, drive out the both side oil seals.
SST 09308−00010
5. INSTALL LH AND RH SIDE OIL SEALS
(a) Using SST and a hammer, drive in a new oil seal until its
surface is flush until the case surface.
SST LH side
09350−32014 (09351−32111, 09351−32130)
RH side
09350−32014 (09351−32130, 09351−32150)
Oil seal drive in depth:
LH side: 5.2 ± 0.5 mm (0.205 ± 0.020 in.)
RH side: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the oil seal lip with MP grease.
6. INSTALL LH AND RH DRIVE SHAFTS
(See page SA−31)
7. FILL ATF AND CHECK ATF LEVEL (See page DI−127)
8. INSTALL ENGINE UNDER COVER

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

DI−186
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) 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
10. Center Differential Control Clutch:
HYDRAULIC TEST
(a) Preparation.
(1) Warm up the ATF.
(2) Remove the test plug and connect SST (See page AX−18 for the location to connect SST).
SST SST 09992−00094 (09992−00111)
CAUTION:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F)
The line pressure test should always be carried out in pairs. One should observe the conditions
of wheels or wheel stoppers outside the vehicle while the other is performing the test.
(b) Measure the center differential clutch control pressure.
(1) Start the vehicle and open the accelerator open 50 % or more and check that the center differen-
tial clutch control pressure is in the range from more than 294 kPa (3.0 kgf/cm
2, 42 psi).
(2) Fully close the accelerator and check that the SST registers 9.8 kPa (0.1 kgf/cm
2, 1.4 psi) or less.
CAUTION:
Confirm safety of the road before checking.
Take care to avoid slip when you start the vehicle on a paved road.
Check the pressure at normal driving ATF temperature 50 − 80°C (122 − 176°F).
Reference:
To measure center differential control pressure to be measured with the solenoid opened by applying voltage
to it, refer to the following:
Prepare a sub−assembly for checking as follows:
Prepare a supply connector (Part No. 90980−10629, or 90980−11143)
Connect a harness of 2 − 3 m (6.6 − 9.8 ft) to terminal 1 of the connector.
Place a bulb of 24W in between the harness.
Connect a harness of 2 − 3 m (6.6 − 9.8 ft) to terminal 3 of the connector.
Connect the inspection’s sub−harness assembly to the solenoid connector of the transfer.
Connect terminal 1 of the sub−harness to the battery’s positive (+) terminal, and terminal 3 of the sub−
harness to the battery’s negative (−) terminal.
Measure the center differential control pressure at idling and when performing the stall test (When 1st
gear).
Engine speedSub−harnessLine pressure kPa (kgf/cm2, psi)
IdlingConnected363 − 422 (3.7 − 4.3, 53 − 61)
Stall (Shift solenoid valve SLD OFF)Connected735 − 863 (7.5 − 8.8, 107 − 125)
Stall (Shift solenoid valve SLD ON)Connected1,324 − 1,549 (13.5 − 15.8, 192 − 225)
All rpmNot connected9.8 (0.1, 1.4) or less

D02250
2 − 3 m
(6.6 − 9.8 ft)
Battery
Adaptor SST 1
90980−10629 90980−111433
24 W
or
Q05128
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−187
1996 RAV4 (RM447U)
Clear the DTC’s after the test.
Evaluation:
ProblemPossible cause
If the measured values at all conditions are higher than the
specificationDifferential control valve defective
Solenoid modulator valve defective
If the measured values at all conditions are lower than the
specificationOil pump defective
Differential control valve defective
Solenoid modulator valve defective
If the pressure is low in the stall test
(Shift solenoid valve SLD ON only)Shift solenoid valve SLD defective
If the measured values are lower than the specification,
when sub−harness is connectedSolenoid modulator valve defective
Differential control valve defective
If the measured values are higher than the specification,
when sub−harness is connectedSolenoid modulator valve defective
Differential control valve defective
11. 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.

DI40U−02
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−189
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−197)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−198)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−197)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−198)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−201)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−203)Shift Solenoid E Electrical
Malfunction
(Shift Solenoid Valve SL)Open or short in shift solenoid valve SL circuit
Shift solenoid valve SL
ECM

P1700
(DI−206)Speed sensor No. 2 Circuit
Malfunction
(Front Speed Sensor)Open or short in front speed sensor circuit
Front speed sensor
ECM

P1715
(DI−209)Rear Wheel Sensor Circuit
Malfunction
(Rear Speed Sensor)Open or short in rear speed sensor circuit
Rear speed sensor
ECM

P1760
(DI−212)Linear Solenoid for Line Pres-
sure Control Circuit Malfunction
(Shift Solenoid Valve ST)Open or short in shift solenoid valve ST circuit
Shift solenoid valve ST
ECM

P1770
(DI−215)Differential Lock Solenoid No. 1
Circuit Malfunction
(Shift Solenoid Valve SLD)Open or short in shift solenoid valve SLD circuit
Shift solenoid valve SLD
ECM

P1780
(DI−218)Park/Neutral Position Switch
MalfunctionShort in park/neutral position switch circuit
Park/neutral position switch
ECM

*:  ...... MIL lights up

DI−194
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) Front or rear wheel is slipping
1. Shift restrict reverse ball
2. Solenoid modulator valve
3. Differential control valve
4. Off−vehicle repair matrix chart


−
Shift point too high or too low1. Secondary regulator valve
Chapter 3: Off−Vehicle Repair
(: A540H Automatic Transaxle Repair Manual Pub. No. RM488U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position
1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)
3. 1st and reverse brake (B
3)
4. 2nd coast brake (B
1)
5. 2nd brake (B
2)
6. Direct clutch (C
2)






Vehicle does not move in reverse position
1. 2nd coast brake (B1)
2. Front planetary gear
3. Rear planetary gear
4. Direct clutch (C
2)
5. O/D direct clutch (C
0)
6. 1st and reverse brake (B
3)






Vehicle does not move in any forward position and reverse posi-
tion
1. Parking lock pawl
2. Oil pump
3. O/D one−way clutch (F
0)
4. O/D direct clutch (C
0)
5. O/D brake (B
0)
6. Front planetary gear
7. Rear planetary gear
8. O/D planetary gear








No lock−up1. Torque converter clutchAX−22
No lock−up OFF1. Torque converter clutchAX−22
Large shock during lock−up1. Torque converter clutchAX−22
E/G stalls when starting off and stopping1. Torque converter clutchAX−22
No up−shift (1st → 2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


No up−shift (2nd → 3rd)1. Direct clutch (C2)
No up−shift (3rd → O/D)1. O/D brake (B0)
No down−shift (2nd → 1st)1. 2nd coast brake (B1)
Harsh engagement (N → R)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Harsh engagement (N → D)1. Forward clutch (C1)
Harsh engagement (1st → 2nd (D position))1. 1st and reverse brake (B3)
Harsh engagement (2nd → 3rd)1. 2nd coast brake (B1)
Harsh engagement (3rd → O/D)
1. O/D direct clutch (C0)
2. O/D brake (B
0)
3. O/D planetary gear



Slip on shudder (Forward and reverse (After warm−up))
1. Torque converter clutch
2. Oil pump
3. No. 1 one−way clutch (F
1)
4. O/D direct clutch (C
0)
AX−22



Slip on shudder (Forward and reverse (Direct after E/G start))1. Torque converter clutchAX−22

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−195
1996 RAV4 (RM447U) Slip on shudder (R range)
1. Direct clutch (C2)
2. O/D direct clutch (C
0)
3. O/D one−way clutch (F
0)



Slip on shudder (1st)1. Forward Clutch (C1)
2. No. 2 one−way Clutch (F
2)


Slip on shudder (2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


Slip on shudder (2nd → 3rd (Up−shift))1. Direct clutch (C2)
Slip on shudder (3rd)1. Direct clutch (C2)
Slip on shudder (O/D)1. O/D brake (B0)
No engine braking (1st − 3rd)1. O/D direct clutch (C0)
No engine braking (1st (L position))1. 1st and reverse brake (B3)
No engine braking (2nd (2 position))2. 2nd coast brake (B1)
Poor acceleration (All positions)1. Torque converter clutch
2. Oil pumpAX−22

Poor acceleration (O/D)1. O/D direct clutch (C0)
2. O/D planetary gear

Poor acceleration (Other than O/D)1. O/D brake (B0)
2. O/D planetary gear

Poor acceleration (Other than 2nd)1. 2nd coast brake (B1)
2. 2nd brake (B
2)


Poor acceleration (1st and 2nd)1. O/D brake (B0)
Poor acceleration (1st and R position)1. 1st and reverse brake (B3)
Poor acceleration (R position)1. Forward clutch (C1)
Front or rear wheel is slipping1. Center differential clutch

D02263
RotorFront Speed Sensor
NS
ECMFront Speed Sensor
Ring Gear
D02264
0 V
5 V/div
2 mec./division DI−206
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
DTC P1700 Speed sensor No. 2 Circuit Malfunction
(Front Speed Sensor)
CIRCUIT DESCRIPTION
The front speed sensor detects the vehicle speed based on revolution of the ring gear and sends signals
to the ECM. An AC voltage is generated in the front speed sensor coil as the ring rear mounted on the ring
gear rotates, and this voltage is sent to the ECM.
The center differential clutch is controlled by the ECM based on the signals from the front speed sensor and
rear speed sensor signals.
DTC No.DTC Detecting ConditionTrouble Area
P1700
All condition below are detects 5,400 times or more continu-
ously
(a) No signal from front speed sensor is input to ECM while 4
pulses of rear speed sensor is sent
(b) Vehicle speed: 18 km/h (11 mph) or more for at 4 sec.
(c) Park / neutral position switch:
OFF (Other than P or N position)
Open or short in front speed sensor circuit
Front speed sensor
ECM
Reference:
Wavefrom between terminals FR
+ and FR− when vehicle speed
is approx. 20 km/h (13 mph).
DI414−01

D02268
Rear Speed Sensor
Transfer
Drive
Gear
D02265
Rear Speed Sensor V4 2
1
V4L−Y
R−L
E5E5 14
13
RR
−
RR+
4 − 6 V ECM
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−209
1996 RAV4 (RM447U)
DTC P1715 Rear Wheel Sensor Circuit Malfunction
(Rear Speed Sensor)
CIRCUIT DESCRIPTION
The rear speed sensor detects the rear wheel speed based on
revolution of the transfer drive gear.
Its construction is the same as that of the front speed sensor
(See page DI−206).
The center differential clutch is controlled by the ECM based on
the signals from the front speed sensor and rear speed sensor
signals.
DTC No.DTC Detecting ConditionTrouble Area
P1715
All conditions below are detected 10 sec. or more
(2 trip detection logic)
(a) No signal rear speed sensor is input to ECM
(b) Vehicle speed: 30 km/h (19 mph) or more
(c) Park / neutral position switch:
OFF (Other than P or N position)
Open or short in rear speed sensor circuit
Rear speed sensor
ECM
WIRING DIAGRAM
DI415−01

D02275
Current flow to solenoid Center
Differential
Control
Pressure
ON
OFF
1 cycleDuty Ratio =
A + B
A
x 100 (%)
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−215
1996 RAV4 (RM447U)
DTC P1770 Differential Lock Solenoid No. 1 Circuit
Malfunction (Shift Solenoid Valve SLD)
CIRCUIT DESCRIPTION
Shift solenoid valve SLD controls the oil pressure applied to the
center differential clutch and maintains the limited slip differen-
tial effects at most appropriate level.
The ECM determines optimum control pressure according to
the signals from the throttle position sensor, front and rear
transaxle revolution sensor and control volume of current flow
to the shift solenoid valve.
The amount of current flow to the solenoid valve is controlled
by the duty ratio* of the ECM output signal. The higher the duty
ratio becomes, the higher the center differential control pres-
sure becomes during the center differential control operation.
*: Duty Ratio
The duty ratio is the ratio of the period of continuity in one cycle.
For example, if A is the period of continuity in one cycle, and B
is the period of non−continuity, then
DTC No.DTC Detection ConditionTrouble Area
P1770
All conditions below are detected 1 sec. or more
(2 trip detection logic)
(a) SLD output signal’s duty ON of 3.3 msecs. or more with
duty ratio of at least 5 % lasts
(b) B
+ voltage: 11 V or more
Open or short in shift solenoid valve SLD circuit
Shift solenoid valve SLD
ECM
DI417−01