lock TOYOTA RAV4 1996 Service Repair Manual

AX0T5−01
Q06565
Q07898
Q07907
Neutral Basic
Line
Groove
Q07906
AX−4
− AUTOMATIC TRANSAXLE (A241E)PARK/NEUTRAL POSITION (PNP) SWITCH
1996 RAV4 (RM447U)
PARK/NEUTRAL POSITION (PNP)
SWITCH
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
3. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Remove the nut and disconnect the shift control cable.
(b) Remove the nut and shift control lever.
(c) Using a screwdriver, pry off the lock plate.
(d) Remove the nut and lock plate.
(e) Remove the 2 bolts and pull out the park/neutral position
switch.
4. INSTALL PARK/NEUTRAL POSITION SWITCH
(a) Temporarily install the park/neutral position switch with
the 2 bolts.
(b) Install a new lock plate and tighten the nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)
(c) Stake the nut with the lock plate.
(d) Adjust the park/neutral position switch (See page
DI−127).
HINT:
Align the groove and park/neutral basic line.
(e) Tighten the 2 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(f) Install the shift control lever with the nut.
(g) Connect the control cable with the nut.
Torque: 13 N·m (135 kgf·cm, 10 ft·lbf)
5. CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
6. INSTALL NO.2 ENGINE UNDER COVER

AX04X−02
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
AX−11
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX0T7−02
Z19320
STPSLS
+
P2
IG
ACC
KLS
+EP1
P
SLS−
Wire Harness Side ABC
AT5027
AT5029
Battery AX−12
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
ConnectorTerminalMeasuring conditionVoltage (V)
A
5 − 4 (ACC − E)Ignition switch ACC10 − 14
1 − 4 (IG − E)Ignition switch ON10 − 14
2 − 4 (STP − E)Depress brake pedal10 − 14
6 − 4 (KLS+ − E)
2. Ignition switch ACC and P position0
3. Ignition switch ACC and except P position7.5 − 11
4. (After−approx. 1 second)5.5 − 10
B1 − 2 (SLS+ − SLS−)
1. Ignition switch ON and P position0
2. Depress brake pedal8.5 − 14
3. Except P position0
C
1 − 2 (P1 − P)1. Ignition switch ON, P position and depress brake pedal0
2. Shift except P position under condition above10 − 14
3 − 2 (P2 − P)1. Ignition switch ACC and P position10 − 14
2. Shift except P position under condition above0
2. INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 26 − 33 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If solenoid operation is not as specified, replace the solenoid.

Q09052
21
Q09053
21
Z193392 (P)1 (P2)
3 (P1)
− AUTOMATIC TRANSAXLE (A241E)SHIFT LOCK SYSTEM
AX−13
1996 RAV4 (RM447U)
3. INSPECT KEY INTERLOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 12.5 − 16.5 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If solenoid operation is not as specified, replace the solenoid.
4. INSPECT SHIFT LOCK CONTROL SWITCH
Inspect that there is continuity between each terminal.
Shift positionTester connectionSpecified value
P position (Release button
is not pushed)2 − 3 (P − P1)Continuity
P position (Release button
is pushed)2 − 3 (P − P1)
2 − 1 (P − P2)Continuity
R, N, D, 2, L position2 − 1 (P − P2)Continuity
If continuity is not as specified, replace the switch.

AX0T8−01
Z18886
RH Drive Shaft
LH Drive Shaft  Snap Ring
64 (650, 47)
 Cotter Pin
Lock Cap
216 (2,200, 159)
 Gasket
49 (500, 36)
7.0 (75, 65 in.·lbf)
62 (630, 46)
48 (490, 35)
Front Exhaust PipeEngine Mounting
Center MemberPS Gear Assembly
Front Suspension Crossmember
Assembly with Stabilizer Bar
RH Engine Under Cover
LH Engine Under Cover
137 (1,400, 101)
206 (2,100, 152)
127 (1,300, 94)
72 (730, 53)

73 (740, 54)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
113 (1,150 83)
 Cotter Pin
 Gasket
35 (360, 26)
64 (650, 47)
64 (650, 47)
19 (194, 14)
25 (250, 18)
46 (470, 34)
27 (280, 20)
25 (250, 18)
9.0 (95, 78 in.·lbf)
64 (650, 47)
9.0 (95, 78 in.·lbf)
37 (380, 27)
13 (135, 10)
39 (400, 29)64 (650, 47)
 GasketStarterEngine Wire
Clamp Plug for Line
Pressure Test
Shift Control
Cable ClipRear End Plate Stiffener Platex 6 Torque Converter
ClutchEngine Coolant Reservoir TankABS RelayAir Intake Connector
Air Cleaner
Case Assembly AX−14
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

AT0953
SST
AX05A−02
AT3306
Hold
Lock
Free
Turn
D00776
AT4184
AX−20
− AUTOMATIC TRANSAXLE (A241E)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
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or if the ring gear is
damaged, replace the drive plate. If installing a new drive plate,
note the orientation of spacers and tighten the bolts.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correcting by
reorienting the installation of the converter clutch.

Q08738
AX128−01
Q06066
Q06109
Q06077NRP AX−6
− AUTOMATIC TRANSAXLE (A540H)PARK/NEUTRAL POSITION (PNP) SWITCH
1996 RAV4 (RM447U)
PARK/NEUTRAL POSITION (PNP)
SWITCH
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
3. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Remove the nut and disconnect the shift control cable.
(b) Remove the nut and shift control lever.
(c) Using a screwdriver, pry off the lock plate.
(d) Remove the nut and lock plate.
(e) Remove the 2 bolts and pull out the park/neutral position
switch.
4. INSTALL AND ADJUST PARK/NEUTRAL POSITION
SWITCH
(a) Install the park/neutral position switch to the manual valve
shaft with the 2 bolts and nut.
(b) Install a new lock plate and tighten the nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)
(c) Stake the nut with the lock plate.
(d) Temporarily install the manual valve lever shaft.
(e) Turn the lever counterclockwise until it stops, then turn it
clockwise 2 notches.
(f) Remove the shaft control lever.

Q06064
AX129−01
AT0103
D00691
D00692
AX−8
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DRAIN ATF
Using a 10 mm hexagon wrench, remove the drain plug, and
drain the ATF into a suitable container.
3. REMOVE OIL PAN AND GASKET
(a) Remove the 17 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE:
Some fluid remain in the oil pan.
4. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Lock carefully at the chips and particles in the oil pan and on the
magnet to anticipate when type of wear you will find in the trans-
axle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bushing wear
5. REMOVE OIL PIPE BRACKET AND STRAINER
(a) Remove the 2 bolts and oil pipe bracket.
(b) Remove the 3 bolts and strainer.
(c) Remove the gasket from the strainer.
6. REMOVE MANUAL VALVE BODY
(a) Remove the 2 bolts and detent spring.

AX04X−03
Q08861
Key Interlock SolenoidStop Light Switch
Shift Lock Override Button Cover
Shift Lock Solenoid
Shift Lock Control Switch
Shift Lock Control ECU HINT:
 The shift indicator housing ordered as
supply parts does not include the cover
of the shift−lock override button.
So, if you replace the shift indicator
housing, install cover from the old
housing into the new housing.
 Install the cover with its cutout facing
toward the rear of the vehicle.
− AUTOMATIC TRANSAXLE (A540H)SHIFT LOCK SYSTEM
AX−15
1996 RAV4 (RM447U)
SHIFT LOCK SYSTEM
LOCATION

AX0ZJ−02
Z19320
STPSLS
+
P2
IG
ACC
KLS
+EP1
P
SLS−
Wire Harness Side ABC
AT5027
AT5029
Battery AX−16
− AUTOMATIC TRANSAXLE (A540H)SHIFT LOCK SYSTEM
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT SHIFT LOCK CONTROL ECU
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the ECU connector.
ConnectorTerminalMeasuring conditionVoltage (V)
A
1 − 3 (ACC − E)IG SW ACC10 − 14
5 − 3 (IG − E)IG SW ON10 − 14
4 − 3 (STP − E)Depress brake pedal10 − 14
2 − 3
(KLS+ − E)
3. IG SW ACC and shift lever at P position0
4. Shift lever at R, N, D, 2, L position7.5 − 11
5. (after approx 1 second)5.5 − 10
B2 − 1
(SLS+ − SLS−)
1. IG SW ON and shift lever at P position0
2. Depress brake pedal8.5 − 14
3. Except P position0
C
3 − 2
(P1 − P)1. IG SW ON, shift lever at P position and depress brake
pedal0
2. Shift except P position under condition above10 − 14
1 − 2
(P2 − P)1. IG SW ACC and shift lever at P position10 − 14
2. Shift except P position under condition above0
2. INSPECT SHIFT LOCK SOLENOID
(a) Disconnect the solenoid connector.
(b) Using an ohmmeter, measure resistance between the ter-
minals.
Standard resistance: 26 − 33 Ω
If resistance value is not as specified, replace the solenoid.
(c) Apply battery positive voltage between the terminals.
Check that the solenoid can be heard operating.
If the solenoid does not operated, replace the solenoid.