oil TOYOTA RAV4 1996 Service Repair Manual

AX0T6−02
Q05259
Q05234
Q06417
Q06418
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
AX−5
1996 RAV4 (RM447U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. REMOVE DRAIN PLUG AND DRAIN ATF
2. REMOVE OIL PAN AND GASKET
Remove the 18 bolts.
NOTICE:
Some fluid will remain in the oil pan. Remove all pan bolts,
and carefully remove the oil pan assembly. Discard the
gasket.
3. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips.
Look carefully at the chips and particles in the pan and the mag-
net to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bearing wear
4. REMOVE OIL STRAINER AND APPLY PIPE BRACKET
NOTICE:
Be careful as some fluid will come out with the oil strainer.
(a) Remove the 3 bolts, oil strainer and gasket.
(b) Remove the 2 bolts and apply pipe bracket.
5. REMOVE OIL PIPE CLAMP AND OIL PIPES
(a) Remove the bolt and oil pipe clamp.
(b) Pry up the both pipe ends with a large screwdriver and re-
move the 5 pipes.
NOTICE:
Be careful not to bend or damage the pipe.

AT3327
Z11664
B A
B
B A
B A
A A C
AT8586
AT8584
Q06418
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
AX−7
1996 RAV4 (RM447U)
11. INSTALL VALVE BODY
(a) Install the valve body.
(b) Connect the manual valve connecting rod.
(c) Install the 17 bolts and wire retainer.
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 30 mm (1.18 in.)
Bolt C: 55 mm (2.17 in.)
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
(d) Connect the throttle cable.
12. CONNECT 3 SOLENOID CONNECTORS
13. INSTALL MANUAL DETENT SPRING
Install the manual detent spring with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
14. INSTALL OIL PIPE CLAMP AND OIL PIPES
(a) Install the 5 pipes with a large screwdriver.
(b) Install the oil pump clamp with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

Q06417
Q05234
Q05259
AX−8
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
15. INSTALL OIL STRAINER AND APPLY PIPE BRACKET
Install the oil strainer, gasket with the 3 bolts.
Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)
HINT:
Replace used the gasket with a new one.
16. INSTALL 2 MAGNETS IN OIL PAN
17. INSTALL OIL PAN AND GASKET
(a) Install a new gasket to the oil pan.
(b) Install the oil pan with the 18 bolts.
Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
18. INSTALL DRAIN PLUG
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
19. FILL ATF AND CHECK ATF (See page DI−127)

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

Q08774
Q08768
D01757
Q08769
C
D
NutAB C
D
A
B
B
B
Nut
Q08770
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−17
1996 RAV4 (RM447U)
15. DISCONNECT FOLLOWING CONNECTORS
Shift solenoid valve SL connector
Park/neutral position switch connector
Vehicle speed sensor connector
16. DISCONNECT 2 OIL COOLER HOSES
Loosen the 2 clips and disconnect the 2 oil cooler hoses.
17. REMOVE 2 POWER STEERING GEAR MOUNTING
BOLTS AND NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
NOTICE:
Support the power steering gear housing securely.
18. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
Remove the 10 bolts, 2 nuts and front suspension crossmem-
ber assembly with stabilizer bar.
Torque:
A bolt: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
B bolt: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
C bolt: 35 N·m (360 kgf·cm, 26 ft·lbf)
D bolt: 72 N·m (730 kgf·cm, 53 ft·lbf)
Nut: 73 N·m (740 kgf·cm, 54 ft·lbf)
19. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

Q06043
SST
AX04M−02
Q06044
SST
− AUTOMATIC TRANSAXLE (A540H)EXTENSION HOUSING OIL SEAL
AX−3
1996 RAV4 (RM447U)
EXTENSION HOUSING OIL SEAL
ON−VEHICLE REPAIR
1. DRAIN TRANSFER OIL
2. REMOVE PROPELLER SHAFT
(See page PR−3)
3. REMOVE EXTENSION HOUSING OIL SEAL
Using SST, remove the oil seal.
SST 09308−00010
4. INSTALL EXTENSION HOUSING OIL SEAL
(a) Using SST and a hammer, driver in a new oil seal.
SST 09325−20010
Oil seal depth: 1.5 ± 0.4 mm (0.059 ± 0.016 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL PROPELLER SHAFT
(See page PR−9)
6. FILL TRANSFER WITH OIL
(See page DI−173)

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.

D00693
Q05896
Q05897
D00645
Q05899
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−9
1996 RAV4 (RM447U)
(b) Remove the 5 bolts and manual valve body with the
manual valve.
(c) Remove the manual valve from the manual valve body.
7. REMOVE OIL PIPE
(a) Remove the bolt and retainer.
(b) Pry up both pipe ends with a large screwdriver and re-
move the 8 pipes.
NOTICE:
Be careful not to bend or damage the pipes.
8. DISCONNECT 3 SOLENOID CONNECTORS
9. REMOVE CONNECTOR CLAMP AND PIPE RETAINER
10. REMOVE B
3 APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.
NOTICE:
Be careful not to bend or damage the pipes.

Z13388
A
B
Q05897
Q05896
Z13389A B
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−11
1996 RAV4 (RM447U)
14. INSTALL CONNECTOR CLAMP AND PIPE RETAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 39 mm (1.54 in.)
Bolt B: 43 mm (1.69 in.)
15. CONNECT 3 SOLENOID CONNECTORS
16. INSTALL OIL PIPE
(a) Using a plastic hammer, install the 8 pipes into their posi-
tions.
NOTICE:
Be careful not to bend or damage the pipes.
(b) Install and tighten the bolt and retainer.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
17. INSTALL MANUAL VALVE BODY AND DETENT
SPRING
(a) Align the manual valve with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Hand−tighten the 5 bolts first. Then, tighten them with a
torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 37 mm (1.46 in.)

Z13390A B
Z13391
A
BA
B
Q06019
Q06064
AX−12
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
(d) Place the detent springs on the manual valve body and
hand−tighten the 2 bolts first.
Then, tighten them with a torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 14 mm (0.55 in.)
Bolt B: 37 mm (1.46 in.)
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
18. INSTALL PIPE BRACKET AND OIL STRAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 53 mm (2.09 in.)
19. INSTALL MAGNETS IN PLACE
NOTICE:
Make sure that the magnets do not interfere with the oil
pipes.
20. INSTALL OIL PAN WITH NEW GASKET
(a) Install a new gasket and oil pan.
(b) Install and tighten 17 bolts.
Torque: 7.9 N·m (80 kgf·cm, 70 in.·lbf)
21. FILL ATF AND CHECK FLUID LEVEL
(a) Using a 10 mm hexagon wrench, install a new gasket and
the drain plug.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Fill the ATF and check the fluid level (See page DI−173).
22. INSTALL NO.2 ENGINE UNDER COVER