shift TOYOTA RAV4 1996 Service Repair Manual

AX051−02
F00484
PositionC1C2C3B1B2Shift Lever
GearShift
Solenoid
Valve No.1 No.2 One−Way Clutch (F
2)
1st & Reverse Brake (B
3)
U/D Brake (B
4)
U/D One−Way Clutch (F
3)U/D Clutch (C
3) Direct Clutch (C
2) 2nd Brake (B
2)Forward Clutch (C
1)
2nd Coast Brake (B
1)
Shift
Solenoid
Valve No.2B
4B3
Front Planetary Gear Unit
F
1F2F3
ON OFF
ON
ON ON
ON OFF OFF ONON ON ON
ON ON OFF
OFFONOFF OFF
OFF OFF OFF
ON
ON
 
 
 
 
 
 


 

 
 
   
  
 
 
 
 

 2nd Neutral ReversePark
1st
O/D3rd
2nd* 2nd 1st
3rd*
1st P
R
N
D
2
L
 : Operating
*: Down−shift only in the 3rd gear for the 2 position and 2nd gear for the L position − no up−shift Rear Planetary Gear Unit
U/D Planetary Gear Unit
No.1 One−Way Clutch (F1)
AX−2
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE SYSTEM
1996 RAV4 (RM447U)
OPERATION

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

AT8584
AT8586
Z11664
B A
B
B A
B A
A A CA
AT3327
Q06411
BA AX−6
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
6. REMOVE MANUAL DETENT SPRING
Remove the bolt and manual detent spring.
7. REMOVE 3 SOLENOID CONNECTORS
8. REMOVE VALVE BODY
(a) Disconnect the throttle cable.
(b) Remove the 11 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.)
(c) Disconnect the manual valve connecting rod.
(d) Remove the valve body.
9. REMOVE 3 SOLENOID VALVES
(a) Remove the 3 solenoid valves.
(b) Remove the O−rings from each of the solenoid valves.
10. INSTALL SHIFT SOLENOID VALVE
(a) Coat new O−rings with ATF and install them to the each
of the solenoid valve.
(b) Install the 3 shift solenoid valves with the 2 bolts.
Torque:
Bolt A: 6.4 N·m (65 kgf·cm, 56 in.·lbf)
Bolt B: 10 N·m (100 kgf·cm, 7 ft·lbf)

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

Q08764
Q08765
Q08766
Q08767
AX−16
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
9. REMOVE ENGINE LEFT MOUNTING BOLT AND NUTS
Torque:
Bolt: 64 N·m (650 kgf·cm, 47 ft·lbf)
Nut: 64 N·m (650 kgf·cm, 47 ft·lbf)
10. REMOVE LEFT AND RIGHT ENGINE UNDER COVERS
11. DRAIN ATF
12. REMOVE LEFT AND RIGHT DRIVE SHAFTS
(See page SA−20)
13. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts and gasket from the exhaust pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Replace used gasket with new gasket.
(b) Remove the 3 nuts, front exhaust pipe and gasket.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Replace used nuts and gasket with new nuts and gasket.
14. DISCONNECT SHIFT CONTROL CABLE
(a) Remove the nut from the control shaft lever.
Torque: 13 N·m (135 kgf·cm, 10 ft·lbf)
(b) Remove the clip and disconnect the control cable.
(c) Remove the 2 shift cable mounting bolts.
Torque: 7.0 N·m (75 kgf·cm, 65 in.·lbf)

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)

AX04L−01
D00690
Planetary Gear Unit
O/D Direct
Clutch (C
0)O/D Brake (B0)1st & Reverse
Brake (B
3)
One−Way Clutch
No.2 (F
2)2nd Brake (B
2)
Forward
Clutch (C
1)2nd Coast
Brake (B
1)
Direct Clutch (C
2)
Input Shaft Front Planetary
Gear
One−Way Clutch
No.1 (F
1) Rear Planetary
Gear
Intermediate
Shaft Counter
Drive Gear
O/D Planetary
Gear O/D One−Way
Clutch (F
0)
Shift Lever
PositionGear Position
C
0C1C2B0B1B2B3F0F1F2
P Parking
Reverse
Neutral
1st
2nd
3rd
O/D R
N
D
2
L1st
2nd
*3rd
1st
*2nd








































*Down−shift only − no up−shift
 : Operating AX−2
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE SYSTEM
1996 RAV4 (RM447U)
OPERATION