1996 TOYOTA RAV4 torque

− 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.

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

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

D02258
Drain
Drain Line
Pressure
Q08777
(+)
(+)
(−) (−)
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−201
1996 RAV4 (RM447U)
DTC P0770 Shift Solenoid E Malfunction
(Shift Solenoid Valve SL)
SYSTEM DESCRIPTION
The ECM uses the signals from the throttle position sensor and
air flow meter to monitor the engagement condition of the lock−
up clutch
Then the ECM compares the engagement condition of the
lock−up clutch with the lock−up schedule in the ECM memory
to detect mechanical trouble of the shift solenoid valve SL,
valve body and torque converter clutch.
DTC No.DTC Detecting ConditionTrouble Area
P0770
Lock−up does not occur when driving in the lock−up range
(normal driving at 80 km/h (50 mph)), or lock−up remains ON
in the lock−up OFF range (2 trip detection logic)Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock−up clutch
INSPECTION PROCEDURE
1 Check shift solenoid valve SL operation.
PREPARATION:
Remove the shift solenoid valve SL from the valve body.
CHECK:
(a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air,
check that the solenoid valve open.
(b) When battery positive voltage is supplied to the solenoid
valve, check that solenoid valve does not leak air.
NG Replace shift solenoid valve SL.
OK
DI411−01

DI−202
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
2 Check valve body (See page DI−192).
NG Repair or replace valve body.
OK
Repair torque converter clutch (See page
AX−22).

S01616
EC−10
− EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 RAV4 (RM447U)
14. REINSTALL EGR VALVE
(a) Install a 2 new gaskets and the EGR valve with the 2 nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Install the EGR pipe with the 2 union nuts.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
15. REINSTALL THROTTLE BODY (See page SF−33)

P03518
: Seal Packing
P01655
Marking
30°
Z17351
2 1 EM−10
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
6. REINSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the head cover with the 4 grommets and nuts. Uni-
formly tighten the nuts in several passes.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
HINT:
Install the grommets so that their markings are as shown in the
illustration.
(e) Install the engine wire protector to the 2 mounting bolts of
the No. 2 timing belt cover in the sequence shown.
(f) Connect the high−tension cords to the spark plugs.
(g) Install the accelerator cable bracket with the 2 bolts.
(h) Connect the accelerator cable to the throttle body.
(i) Connect the accelerator cable to the clamp on the intake
manifold.
(j) Connect the accelerator cable to the clamp on the gener-
ator bracket.
(k) Connect the A/T throttle control cable to the throttle body.
(l) Connect the PCV hose to the air cleaner hose.
(m) Connect the PCV hose to the intake manifold.
7. CONNECT PS RESERVOIR