1996 TOYOTA RAV4 torque

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)

Z18887
A
A
A
B
Q08772
Q08773
A
B AX−18
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
20. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
A bolt: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
B bolt: 19 N·m (195 kgf·cm, 14 ft·lbf)
21. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLT
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley set bolt by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
First install the gray bolt. Then install 5 black bolts while turning
the crankshaft to grain access.
22. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
23. REMOVE TRANSAXLE
Remove the rear side transaxle mouting 2 bolts and transaxle.
Torque:
A bolt: 25 N·m (250 kgf·cm, 18 ft·lbf)
B bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)

AT3412
AX059−03
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH
Using calipers and a straight edge, measure from the installed
surface to front surface of the transaxle housing.
Correct distance: More than 12.75 mm (0.502 in.)
2. INSTALL TRANSAXLE
Installation is in the reverse order of removal (See page
AX−15).
HINT:
After installation, check and inspect items as follows.
Fluid level (See page DI−127)
Front wheel alignment (See page SA−4)
Road test the vehicle

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.

− AUTOMATIC TRANSAXLE (A241E)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX−21
1996 RAV4 (RM447U)
HINT:
Mark the position of the torque converter clutch to ensure cor-
rect installation.

Q08739
AX04N−01
Q06120
Vehicle Speed
SensorO−Ring
Clip Driven Gear
Q08737
Q06119O−Ring
AX−4
− AUTOMATIC TRANSAXLE (A540H)VEHICLE SPEED SENSOR
1996 RAV4 (RM447U)
VEHICLE SPEED SENSOR
ON−VEHICLE REPAIR
1. REMOVE FRONT SPEED SENSOR
(a) Remove the air cleaner assembly.
(b) Disconnect the front speed sensor connector.
(c) Remove the bolt and front speed sensor assembly.
(d) Remove the clip and speedometer driven gear from the
front speed sensor.
(e) Remove the O−ring from the front speed sensor.
2. INSTALL FRONT SPEED SENSOR ASSEMBLY
(a) Coat a new O−ring with ATF and install it to the front
speed sensor.
(b) Install the speedometer driven gear to the front speed
sensor with the clip.
(c) Install the front speed sensor assembly with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Connect the front speed sensor connector.
(e) Install the air cleaner assembly.
3. REAR SPEED SENSOR
(a) Remove the air cleaner assembly.
(b) Disconnect the rear speed sensor connector.
(c) Remove the bolt and rear speed sensor.
(d) Remove the O−ring from the rear speed sensor.
4. INSTALL REAR SPEED SENSOR
(a) Coat a new O−ring with ATF and install it to the rear speed
sensor.
(b) Install the rear speed sensor with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(c) Connect the rear speed sensor connector.
(d) Install the air cleaner assembly.

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.

Q06078
Neutral
Basic
Line
Groove
Q08738
− AUTOMATIC TRANSAXLE (A540H)PARK/NEUTRAL POSITION (PNP) SWITCH
AX−7
1996 RAV4 (RM447U)
(g) Adjust the park/neutral position switch
(See page AX−6).
HINT:
Align the groove and park/neutral basic line
(h) Tighten the 2 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(i) Install the shaft control lever with the nut.
Torque: 12.7 N·m (130 kgf·cm, 9 ft·lbf)
(j) Connect the control cable with the nut.
5. CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
6. INSTALL NO.2 ENGINE UNDER COVER