1996 TOYOTA RAV4 remove transaxle

Q06064
AX129−01
AT0103
D00691
D00692
AX−8
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DRAIN ATF
Using a 10 mm hexagon wrench, remove the drain plug, and
drain the ATF into a suitable container.
3. REMOVE OIL PAN AND GASKET
(a) Remove the 17 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE:
Some fluid remain in the oil pan.
4. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Lock carefully at the chips and particles in the oil pan and on the
magnet to anticipate when type of wear you will find in the trans-
axle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bushing wear
5. REMOVE OIL PIPE BRACKET AND STRAINER
(a) Remove the 2 bolts and oil pipe bracket.
(b) Remove the 3 bolts and strainer.
(c) Remove the gasket from the strainer.
6. REMOVE MANUAL VALVE BODY
(a) Remove the 2 bolts and detent spring.

D00693
Q05896
Q05897
D00645
Q05899
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−9
1996 RAV4 (RM447U)
(b) Remove the 5 bolts and manual valve body with the
manual valve.
(c) Remove the manual valve from the manual valve body.
7. REMOVE OIL PIPE
(a) Remove the bolt and retainer.
(b) Pry up both pipe ends with a large screwdriver and re-
move the 8 pipes.
NOTICE:
Be careful not to bend or damage the pipes.
8. DISCONNECT 3 SOLENOID CONNECTORS
9. REMOVE CONNECTOR CLAMP AND PIPE RETAINER
10. REMOVE B
3 APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.
NOTICE:
Be careful not to bend or damage the pipes.

D00694
OR0038
Z13387A B CDC
C
D00696
AX−10
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
11. REMOVE VALVE BODY
(a) Remove the 10 bolts.
(b) Disconnect the throttle cable from the cam and remove
the valve body.
12. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the cable
end into the slot.
(b) Raise up the valve body into place.
NOTICE:
Do not entangle the solenoid wire.
(c) Install and tighten the 10 bolts.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Hand−tighten the 10 bolts first, then torque with a torque
wrench.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 32 mm (1.26 in.)
Bolt C: 43 mm (1.69 in.)
Bolt D: 55 mm (2.17 in.)
13. INSTALL B
3 APPLY PIPE
NOTICE:
Be careful not to bend or damage the pipe.

Q06117
AX04R−02
Q06068
Q057310.8 − 1.5 mm (0.031 − 0.059 in.) 200 mm
(7.87 in.)
− AUTOMATIC TRANSAXLE (A540H)THROTTLE CABLE
AX−13
1996 RAV4 (RM447U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM LINKAGE
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
3. REMOVE VALVE BODY
(See page AX−8)
4. REMOVE THROTTLE CABLE
(a) Remove the bolt and pull the cable out of the transaxle
case.
(b) Remove the O−ring from the throttle cable.
5. INSTALL THROTTLE CABLE INTO TRANSAXLE
CASE
If the throttle cable is new do the following operations (a) − (c).
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until a slight resistance is felt,
and hold it.
(c) Stake the stopper 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
(d) Install a new O−ring to the throttle cable.
(e) Make sure to push it in all the way.
(f) Install and torque the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
6. INSTALL VALVE BODY
(See page AX−8)
7. CONNECT THROTTLE CABLE TO LINKAGE
8. ADJUST THROTTLE CABLE
(See page DI−173)
9. INSTALL PARK/NEUTRAL POSITION SWITCH
(See page AX−6)
10. TEST DRIVE VEHICLE

Q06041
SST
AX04S−01
Q06072
Q06040SST
Q06042
SST AX−14
− AUTOMATIC TRANSAXLE (A540H)SIDE GEAR SHAFT OIL SEAL
1996 RAV4 (RM447U)
SIDE GEAR SHAFT OIL SEAL
ON−VEHICLE REPAIR
1. REMOVE BOTH DRIVE SHAFTS
(See page SA−20)
2. REMOVE LH SIDE GEAR SHAFT OIL SEAL
Using SST, pull out the oil seal.
SST 09308−00010
3. REMOVE RH SIDE GEAR SHAFT OIL SEAL
Using a screwdriver, remove the oil seal.
4. INSTALL LH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, driver in a new oil seal.
SST 09608−32010, 09950−70010 (09951−07100)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
5. INSTALL RH SIDE GEAR SHAFT OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09608−32010, 09950−70010 (09951−07100)
Oil seal depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
6. INSTALL BOTH DRIVE SHAFTS (See page SA−31)
7. CHECK FLUID LEVEL (See page DI−173)

Q06113
AX04U−02
Q05857
Z19463
Q05858
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See page
EM−68)
2. REMOVE STARTER
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
Bolt A: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
Bolt B: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley nut 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.
Coat the threads of the bolts with sealant.
Sealant: Part No. 08833 − 00070, THREE BONDS 1324
or equivalent
Tighten the bolts evenly.
First install dark green colored bolt and then the 5
bolts.
6. DISCONNECT CONNECTORS AND WIRE HARNESS
FROM TRANSAXLE

Q08839
Q06112
Z17589
AX−20
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
7. REMOVE CENTER STIFFENER PLATE
Remove the 4 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE TRANSAXLE WITH TRANSFER ASSEMBLY
(a) Remove the 2 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 5 transaxle mounting bolts.
Torque:
14 mm head bolt: 64 N·m (650 kgf·cm, 47 ft·lbf)
12 mm head bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)
(c) Separate the transaxle assembly.

AT4184
− AUTOMATIC TRANSAXLE (A540H)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX−23
1996 RAV4 (RM447U)
3. MEASURE TORQUE CLUTCH CONVERTER SLEEVE
RUNOUT
(a) Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator and measure the torque con-
verter clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter clutch.
HINT:
Mark the position of the converter clutch to ensure correct
installation.
(b) Remove the torque converter clutch.