1996 TOYOTA RAV4 shift cable

D02249
1
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−185
1996 RAV4 (RM447U)
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 parts. One should observe the conditions
of wheels or wheel stopper outside the vehicle while the other is performing the test.
(b) Measure the line pressure.
(1) Fully apply the parking brake and chock the 4 wheels.
(2) Start the engine and check idling speed.
(3) Step down strongly on the brake pedal with your left foot and shift into the D position.
(4) Measure the line pressure when the engine is idling speed.
(5) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine
speed reaches stall speed.
(6) Only when the shift solenoid valve ST is opened:
Apply battery positive voltage between terminal of the solenoid connector and body ground.
(7) In the same way, perform the test in the R position.
Automatic Transaxle Idling kPa (kgf/cm2, psi) Stall kPa (kgf/cm2, psi)
* D position (Shift solenoid valve ST open)530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
D position (Shift solenoid valve ST close)363 − 442 (3.7 − 4.3, 53 − 61)736 − 863 (7.5 − 8.8, 106 − 125)
R position530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
*: When battery voltage is supplied to terminal 4 of the solenoid connector and body ground, the shift sole-
noid valve ST valve is open.
If the measured pressures are not with in the specification, recheck the throttle cable adjustment and perform
a retest.
(8) Clear the DTC’s after the test.
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher than speci-
fiedThrottle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured value in all positions are lower than speci-
fied
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective

− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−193
1996 RAV4 (RM447U) No lock−up
1. Lock−up relay valve
2. Off−vehicle repair matrix chart
−
No lock− up OFF1. Lock−up relay valve
2. Off−vehicle repair matrix chart
−
No kick−down
1. Throttle cable
2. 1−2 shift valve
3. 2−3 shift valve
4. 3−4 shift valve
5. Down shift plug




No engine braking (1st (L position))
1. Low coast modulator valve
2. Low coast modulator valve
3. Off−vehicle repair matrix chart

−
No engine braking (2nd (2 position))
1. 2nd coast modulator valve
2. 2nd lock valve
3. Off−vehicle repair matrix chart

−
No up−shift (1st → 2nd)1. 1−2 shift valve
2. Off−vehicle repair matrix chart
−
No up−shift (2nd → 3rd)1. 2−3 shift valve
2. Off−vehicle repair matrix chart
−
No up−shift (3rd → O/D)1. 3−4 shift valve
2. Off−vehicle repair matrix chart
−
No down−shift (O/D → 3rd)1. 3−4 shift valve
2. Off−vehicle repair matrix chart
−
No down shift (3rd → 2nd)1. 2−3 shift valve
2. Off−vehicle repair matrix chart
−
No down shift (2nd → 1st)1. 1−2 shift valve
2. Off−vehicle repair matrix chart
−
Harsh engagement (N → R)1. No. 1 and No. 2 accumulator control valve
2. Off−vehicle repair matrix chart
−
Harsh engagement (N → D)1. C1 accumulator
2. Off−vehicle repair matrix chart
−
Harsh engagement (N → L)1. Low coast modulator valve
Harsh engagement (1st → 2nd (D position))1. B2 accumulator
2. Off−vehicle repair matrix chart
−
Harsh engagement (1st → 2nd (2 position))1. 2nd coast modulator valve
Harsh engagement (1st → 2nd → 3rd)1. Throttle modulator valve
2. No. 1 and No. 2 accumulator control valve

Harsh engagement (1st → 2nd → 3rd → O/D)1. No. 1 and No. 2 accumulator control valve
Harsh engagement (2nd → 3rd)1. C2 accumulator
Harsh engagement (3rd → O/D)1. B0 accumulator
2. Off−vehicle repair matrix chart
−
Harsh engagement (O/D → 3rd)1. C0 accumulator
2. B
0 accumulator


Harsh engagement (3rd → 2nd)
1. B2 accumulator
2. C
0 accumulator
3. B
0 accumulator
4. 2nd coast modulator valve
5. Off−vehicle repair matrix chart




−
Sliper shudder in forward and reverse (Directry after E/G start)
1. Pressure relief valve
2. Oil starter
3. Off−vehicle repair matrix chart
AX−8
−

DI42M−01
DI−336
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the DTC check but the trouble still occurs (reappears), troubleshoot for
each problem symptom, checking the circuits for each symptom in the order given in the table below. Pro-
ceed to the page indicated for each circuit.
HINT:
If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart
for each circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still reappears even through there are no abnormalities in any of the other circuits, then
check or replace the cruise control ECU as the last step.
SymptomSuspect AreaSee page
SET not occurring or CANCEL occurring.
(DTC is Normal)
1. Main Switch Circuit (Cruise Control Switch)
2. Vehicle Speed Sensor Circuit
3. Control Switch Circuit (Cruise Control Switch)
4. Stop Light Switch Circuit
5. Park/Neutral Position Switch Circuit
6. Clutch Switch Circuit
7. Actuator
8. Cruise Control ECUDI−371
DI−346
DI−348
DI−351
DI−360
DI−363
DI−338
IN−30
SET not occurring or CANCEL occurring.
(DTC does not output)1. ECU Power Source Circuit
2. Cruise Control ECUDI−366
IN−30
Actual vehicle speed deviates above or below the set speed.
1. Actuator Control Cable
2. Vehicle Speed Sensor Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−346
DI−338
IN−XXX
Gear shifting is frequent between 3rd and OD when driving on
uphill road. (Hunting)1. Electronically Controlled Transaxle Communication
Circuit
2. Cruise Control ECUDI−357
IN−30
Cruise control not cancelled, even when brake pedal is de-
pressed.
1. Actuator Control Cable
2. Stop Light Switch Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−351
DI−338
IN−30
Cruise control not cancelled, even when transmission is shifted to
except D position. (A/T)
1. Actuator Control Cable
2. Park/Neutral Position Switch Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−360
DI−338
IN−30
Cruise control not cancelled, even when clutch pedal depressed.
(M/T)
1. Actuator Control Cable
2. Clutch Switch Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−363
DI−338
IN−30
Control switch does not operate.
(SET/COAST, ACC/RES, CANCEL not possible)
1. Actuator Control Cable
2. Control Switch Circuit (Cruise Control Switch)
3. Actuator
4. Cruise Control ECUDI−376
DI−363
DI−338
IN−30
SET possible at 40 km/h (25 mph) or less, or CANCEL does not
operate at 40 km/h (25 mph) or less.
1. Actuator Control Cable
2. Vehicle Speed Sensor Circuit
3. Actuator
4. Cruise Control ECUDI−376
DI−346
DI−338
IN−30
Poor response in ACCEL and RESUME modes.
1. Actuator Control Cable
2. Electronically Controlled Transaxle Communication
Circuit
3. Control Switch Circuit (Cruise Control Switch)
4. Actuator
5. Cruise Control ECUDI−3764
DI−357
DI−363
DI−338
IN−30

S01374
Cover
Connector
− ENGINE MECHANICALENGINE UNIT
EM−79
1996 RAV4 (RM447U)
25. INSTALL GENERATOR (See page CH−19)
26. INSTALL CHARCOAL CANISTER
27. CONNECT ENGINE WIRE TO RELAY BOX NO. 2
(a) Connect the engine wire to the relay block No.2 with the
2 nuts.
(b) Connect the connector.
(c) Install the upper cover.
(d) Connect the relay block No. 2 to the body with the 2 bolts.
28. INSTALL ACCELERATOR CABLE TO THROTTLE
BODY, CABLE BRACKET AND CLAMPS
29. INSTALL AIR CLEANER CASE AND CAP
30. INSTALL BATTERY
31. FILL WITH TRANSAXLE OIL
32. FILL WITH ENGINE OIL
33. FILL WITH ENGINE COOLANT
34. START ENGINE AND CHECK FOR LEAKS
35. PERFORM ENGINE ADJUSTMENT
36. CHECK FRONT WHEEL ALIGNMENT
37. INSTALL ENGINE UNDER COVERS
38. INSTALL ENGINE HOOD
39. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points
and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS

148
CRUISE CONTROL
CURRENT IS APPLIED AT ALL TIMES THROUGH THE STOP FUSE TO TERMINAL 2 OF THE STOP LIGHT SW, AND ALSO THROUGH
THE DOME FUSE TO TERMINAL 15 OF THE CRUISE CONTROL ECU.
WITH THE IGNITION SW TURNED TO ON, CURRENT FLOWS THROUGH THE GAUGE FUSE TO TERMINAL 8 OF THE COMBINATION
METER AND THE CURRENT THROUGH THE DOME FUSE FLOWS TO TERMINAL 15 OF THE CRUISE CONTROL ECU.
WHEN THE IGNITION SW IS ON AND THE CRUISE CONTROL MAIN SW IS TURNED ON, A SIGNAL IS INPUT FROM TERMINAL 5 OF THE
CRUISE CONTROL SW TO TERMINAL 19 OF THE CRUISE CONTROL ECU. AS A RESULT, THE CRUISE CONTROL ECU FUNCTIONS
AND THE CURRENT FLOWS FROM THE ECU-IG FUSE TO TERMINAL 14 OF THE CRUISE CONTROL ECU TO TERMINAL 13 OF THE
CRUISE CONTROL ECU " GROUND, AND THE CRUISE CONTROL SYSTEM IS IN A CONDITION READY FOR OPERATION.
AT THE SAME TIME, THE CURRENT THROUGH THE GAUGE FUSE FLOWS TO TERMINAL 8 OF THE CRUISE CONTROL INDICATOR
LIGHT "TERMINAL 6 "TERMINAL 7 OF THE CRUISE CONTROL ECU "TERMINAL 13 "GROUND, CAUSING THE CRUISE
CONTROL INDICATOR LIGHT TO LIGHT UP, INDICATING THAT THE CRUISE CONTROL IS READY FOR OPERATION.
1. SET OPERATION
WHEN THE CRUISE CONTROL MAIN SW IS TURNED ON AND THE SET SW IS PUSHED WITH THE VEHICLE SPEED WITHIN THE SET
LIMIT (APPROX. 40 KM/H, 25 MPH TO 200 KM/H, 124 MPH), A SIGNAL IS INPUT TO TERMINAL 18 OF THE CRUISE CONTROL ECU AND
THE VEHICLE SPEED AT THE TIME THE SET SW IS RELEASED IS MEMORIZED IN THE ECU AS THE SET SPEED.
2. SET SPEED CONTROL
DURNING CRUISE CONTROL DRIVING, THE ECU COMPARES THE SET SPEED MEMORIZED IN THE ECU WITH THE ACTUAL VEHICLE
SPEED INPUT INTO TERMINAL 20 OF THE CRUISE CONTROL ECU FROM THE SPEED SENSOR, AND CONTROLS THE CRUISE
CONTROL ACTUATOR TO MAINTAIN THE SET SPEED.
WHEN THE ACTUAL SPEED IS LOWER THAN THE SET SPEED, THE ECU CAUSES THE CURRENT TO THE CRUISE CONTROL
ACTUATOR TO FLOW FROM TERMINAL 12 OF THE CRUISE CONTROL ECU "TERMINAL 6 OF THE CRUISE CONTROL ACTUATOR "
TERMINAL 7 "TERMINAL 11 OF THE CRUISE CONTROL ECU. AS A RESULT, THE MOTOR IN THE CRUISE CONTROL ACTUATOR IS
ROTATED TO OPEN THE THROTTLE VALVE AND THE THROTTLE CABLE IS PULLED TO INCREASE THE VEHICLE SPEED. WHEN THE
ACTUAL DRIVING SPEED IS HIGHER THAN THE SET SPEED, THE CURRENT TO THE CRUISE CONTROL ACTUATOR FLOWS FROM
TERMINAL 11 OF THE ECU "TERMINAL 7 OF THE CRUISE CONTROL ACTUATOR "TERMINAL 6 "TERMINAL 12 OF THE CRUISE
CONTROL ECU.
THIS CAUSES THE MOTOR IN THE CRUISE CONTROL ACTUATOR TO ROTATE TO CLOSE THE THROTTLE VALVE AND RETURN THE
THROTTLE CABLE TO DECREASE THE VEHICLE SPEED.
3. COAST CONTROL
DURING THE CRUISE CONTROL DRIVING, WHILE THE COAST SW IS ON, THE CRUISE CONTROL ACTUATOR RETURNS THE
THROTTLE CABLE TO CLOSE THE THROTTLE VALVE AND DECREASE THE DRIVING SPEED. THE VEHICLE SPEED WHEN THE COAST
SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET SPEED.
4. ACCEL CONTROL
DURING CRUISE CONTROL DRIVING, WHILE THE ACCEL SW IS TURNED ON, THE CRUISE CONTROL ACTUATOR PULLS THE
THROTTLE CABLE TO OPEN THE THROTTLE VALVE AND INCREASE THE DRIVING SPEED.
THE VEHICLE SPEED WHEN THE ACCEL SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET
SPEED.
5. RESUME CONTROL
UNLESS THE VEHICLE SPEED FALLS BELOW THE MINIMUM SPEED LIMIT (APPROX. 40 KM/H, 25 MPH) AFTER CANCELING THE SET
SPEED BY THE CANCEL SW, PUSHING THE RESUME SW WILL CAUSE THE VEHICLE TO RESUME THE SPEED SET BEFORE
CANCELLATION.
6. MANUAL CANCEL MECHANISM
IF ANY OF THE FOLLOWING OPERATIONS OCCURS DURING CRUISE CONTROL OPERATION, THE MAGNETIC CLUTCH OF THE
ACTUATOR TURNS OFF AND THE MOTOR ROTATES TO CLOSE THE THROTTLE VALVE AND THE CRUISE CONTROL IS RELEASED.
*PLACING THE SHIFT LEVER EXCEPT Dº POSITION (PARK/NEUTRAL POSITION SW EXCEPT Dº POSITION). SIGNAL IS NOT INPUT
TO TERMINAL 2 OF THE ECUº
*DEPRESSING THE BRAKE PEDAL (STOP LIGHT SW ON). SIGNAL INPUT TO TERMINAL 16 OF THE ECUº
*PUSHING THE CANCEL SW (CANCEL SW ON). SIGNAL INPUT TO TERMINAL 18 OF THE ECUº
SYSTEM OUTLINE

MX01Z−08
− MANUAL TRANSAXLETROUBLESHOOTING
MX−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
14.Oil (Level low) 2WD
4WD
15. Oil (Wrong) 2WD
4WD
16.Gear (Worn or damaged)
17.Bearing (Worn or damaged)MX−3
MX−9
MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
MX−12
MX−78
MX−79
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX−77
MX−12
MX−29
MX−36
MX−12
MX−29
MX−36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX−12
MX−12
MX−79
MX−12
MX−79
MX−12
MX−79
Tight corner braking1. Differential, Center differential (Faulty)MX−58
MX−72

MX065−01
D01958
Shift Lever Knob
Side Trim Cover
Side Trim Cover
Shift Control Cable Grommet Retainer
Shift Lever Assembly Select Control Cable
N·m (kgf·cm, ft·lbf) : Specified torqueWasherClip
Washer GrommetRetainerConsole Box Boot
12 (120, 9)
4.9 (50, 43 in.·lbf)
4.9 (50, 43 in.·lbf)
Clip Clip
Clip
Clip
ClipWasher
Bracket
− MANUAL TRANSAXLESHIFT LEVER AND CONTROL CABLE
MX−77
1996 RAV4 (RM447U)
SHIFT LEVER AND CONTROL CABLE
COMPONENTS