1996 TOYOTA RAV4 Service Repair Manual

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.

AX04K−02
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE SYSTEM
AX−1
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE SYSTEM
PRECAUTION
When working with FIPG material, you must observe the followings.
Using a razor blade and a gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section.

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

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)